Troubleshooting Procedures, Equipment needed | Honeywell UDC2500

Troubleshooting/Service

If the symptom still persists, refer to the installation section in this manual to ensure proper installation and proper use of the controller in your system.

7.7 Troubleshooting Procedures

Introduction

The troubleshooting procedures are listed in numerical order as they appear in Table 7-4.Each procedure lists what to do if you have that particular failure and how to do it or where to find the data needed to accomplish the task.

WARNING—SHOCK HAZARD

TROUBLESHOOTING MAY REQUIRE ACCESS TO HAZARDOUS LIVE

CIRCUITS, AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE

PERSONNEL. MORE THAN ONE SWITCH MAY BE REQUIRED TO DE-

ENERGIZE UNIT BEFORE SERVICING.

Equipment needed

You will need the following equipment in order to troubleshoot the symptoms listed in the tables that follow:

•Multimeter – Capable of measuring millivolts, milliamps and resistance.

•Calibration sources – T/C, mV, Volt, etc.

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Honeywell UDC2500 manual Troubleshooting Procedures, Equipment needed

Contents

UDC2500 Universal Digital Controller Product Manual Copyright 2007 by Honeywell Revision 5 April WARRANTY/REMEDY Telephone AbstractContacts World Wide Web Symbol Definition Symbol Definitions Contents 136 Monitoring and Operating the Controller 180 151158 177 226 220221 222 Tables Introduction Introduction Figures Wiring Connections for Calibrating Current Output Page Easy to Read Displays FeaturesOverview Function UDC2500 Operator Interface all display items shown Mount Anywhere MAN Function of Displays and Keys1Function of Displays and Keys Overview Process Instrument Explorer Software Depiction of infrared communications CE Conformity Europe Introduction What’s in this section? Introduction Condensed Specifications Condensed SpecificationsPre-installation Information Alarm Outputs RTU Frequency Hz Environmental and Operating Conditions Instructions Model Number Interpretation Model Number Interpretation Control Relays Control and Alarm Relay Contact InformationAlarm Relays Alarm Relay Contact Information Physical Considerations Overall DimensionsMounting Step Action Mounting ProcedureMounting Method Wiring Bundle No Wire Functions Permissible Wiring Bundling Universal Output Functionality and Restrictions Wiring DiagramsIdentify Your Wiring Requirements Tpsc INU Composite Wiring Diagram Wiring the Controller Line Neutral Voltage L2/N Earth Ground HotAC/DC RTD Input #1 Time Simplex Input #2Volts Input Milliamps Input Solid State Relay Output 10 Open Collector Output 12 Current Output 11 Dual Electromechanical Relay Option Output Open CW 15 RS-422/485 Communications Option Connections 17 Auxiliary Output and Digital Inputs Option Connections 12 + 26 + Configuration Topics Configuration Set Up Group Function Prompts Configuration Prompt HierarchyConfiguration Prompt Hierarchy Upper Display = SET Configuration ProcedureProcedure Configuration Procedure Rate T Tuning Set Up Group Gain MINRPM Manrst Secur ALL Configuration is CompleteI2 MIN I2 RPM RN HLD DisableEnable Automa TI MIN SP Ramp Set Up GroupSP Ramp Euhrup FinlspSetpoint Ramp Final Setpoint Sprate Strseg EuhrdnSpprog Setpoint RAMP/SOAK Program Pvstrt StateDIS Hold Accutune Set Up Group Accutune FuzzyFuzzy Overshoot Suppression Tune Current Accutune Process 304 Accutune Error STATUS-When anAT ERR Onof Algorithm Set Up GroupCtralg 401 Derivative Rate-Regulates OuthysPida Proportional Gain-Regulates Three Position Step Control PD with Manual Reset is usedManrst in the Tuning Set Up group Pdmr Start TimerPeriod Incrmt ResetDisp With Control algorithm prompt Tpsc Output Set Up GroupOutalg 501 Current Duplex Range Algorithm CrangeOutrng Current Duplex Range Full English Numeric Code Current Duplex Range SPLIT-ThisFor Example MTR TI RLY TYP Relay Cycle Time IncrementMech Electromechanical RELAY-Cycle 601 Input 1 Actuation Type This Input 1 Set Up GroupIN1TYP IN1 HI XMITR1Transmitter Characterization FILTR1 IN1 LORATIO1 Bias Emiss DownDownscale Burnout will force Nofs XMITR2 Input 2 Set Up GroupIN2TYP 701 Input 2 Actuation Type This FILTR2 IN2 HIIN2 LO RATIO2 801 Control Set Up GroupNumber of Tuning Parameter Pidset LSP’S TWO Sets PV AutomaticTWO Sets SP Automatic SW VAL PWR UP Power UP Controller ModeRspsrc SP TRK Action PwroutThree Position Control Step Three Position Step Failsafe BandHyst Failsf Minrpm Failsafe ModeFsmode No Auxiliary Output Options GroupAuxout Auxiliary Output Selection Auxiliary Output LOW Scaling Deviation Process Variable0PCT No Digital Input Selections Auxiliary Output High ScalingDIGIN1 Keyboard LOCKOUT-Contact closure External SP Program ResetInhibit Integral RESET-Contact Manual Failsafe OUTPUT-Controller Output Tracks Input 2-Contact Initiate Limit Cycle TUNING-ContactSetpoint INITIALIZATION-Contact To Remote SETPOINT-Contact closure DIGIN2 DI1COMDigital Input 1 Combination Plus RUN Setpoint Irenab Communications GroupComsta Communications Selection Sdenab Shed Controller Mode and OutputTxdly Wsflt Percent ShdspShed Setpoint Recall Units Alarms Set Up Group TC F Deviation from LSP 2 NoteTC W Thermocouple Warning Note A1S1HL High AlarmLOW Alarm A1S1VA A1S2TY A1S1EVBeginning of Segment END of Segment A2S2VA A2S1HLA2S1EV A2S2TY Diagal ALARM1Block Decimal Point LOCATION-This Display Set Up GroupDecmal 1201 Lnguag FreqDisply Lwrdsp Ethernet Configuration Screen 16 P.I.E. Tool Ethernet and Email Configuration Screens Email Configuration Screen Configuration Configuration Record Sheet COM AlarmsContrl Option Whats in this section? Monitoring and Operating the Controller Entering a Security Code Operator Interface Lockout levels Lockout FeatureProcedure to Enter a Security Code Individual key lockout Key error Annunciators Monitoring Your Controller 4.5.1 Annunciators Lower Display Key Parameter Prompts Viewing the operating parameters Diagnostic Messages Diagnostic Messages Functional Overview Block Diagram of the UDC2500 Controller Exceptions Access the ValuesAuto-only Mode Single Display Functionality Lower Display Prompt Upper Display Value Comments Single Display Parameters Upper Display = PV Value Start Up Procedure for OperationProcedure for Starting Up the Controller Control Modes Mode DefinitionsControl Mode Definitions Step Operation Press Result Select Until you see What happens when you change modesSetpoints Changing Control Modes Dual Display Only Configuration check TimerSwitching between setpoints 10 Procedure for Switching Between Setpoints Operation Viewing Times Accutune Tuning indicators Tune for Duplex Heat/Cool 11 Procedure for Starting TuneTune for Simplex Outputs Configuration Check for Duplex Using Automatic Tune at start-up for Duplex Heat/CoolUsing Blended Tune at start-up for Duplex Heat/Cool Using Manual Tune at start-up for Duplex Heat/Cool 108 Aborting Accutune Error Codes16 Procedure for Accessing Accutune Error Codes 17 Accutune Error Codes Completing Accutune Using Two Sets of Tuning ConstantsConfiguration Fuzzy Overshoot Suppression Upper Display = SET Lower Display = Contrl Set up Procedure18 Set Up Procedure Upper Display = the switchover value Upper Display = the PV value Lower Display = Pids X X= 1 or Alarm SetpointsUpper Display = SET Lower Display = Alarms Upper Display = PV Three Position Step Control AlgorithmEstimated Motor Position Display 100 = motor goes to open position Upper Display = rangeExcept 3 Position Step = motor goes to closed position PV Hot Start Setting Failsafe ModeSet Failsafe Mode 23 Procedure for Setting a Failsafe Mode Setpoint Rate/Ramp/Program Overview 24 Running a Setpoint Ramp 19Setpoint RampRUN/HOLD key 20Setpoint Rate Power OutagePower outages Setpoint Ramp/Soak Programming Review program data and configurationProgram Contents 25 Program Contents Ramp unit Contents Definition Ramp/soak profile example To Begin SEGRP Unit Soak Time Ramp Time Soak SP Program record sheet Function Press Result Run/Monitor the programRun/Monitor functions 26 Run/Monitor Functions Lower Display = Recxx Power outage Digital input remote switch operationLower Display = XXHH.MM Loop Data 22 P.I.E. Tool Maintenance Screens Loop Data Maintenance Screen Alarm Details Maintenance Screen Loop Data Alarm Details Digital Input Details Screen Loop Data Digital Input Details Status Data Status Data Maintenance Screen Ethernet Status 10 Ethernet Status Maintenance Screen Configuring the Controller via Infrared Communications Configuring your Ethernet Connection 12 Online Configuration 14 Ethernet Communications Type Selection Configuring the Controller via Ethernet Communications 15 Ethernet Communications Address 16 Configuration Upload in Progress Input Calibration Select the Range Values Minimum and Maximum Range ValuesCalibration Steps RP20-RP40 Sensor Type PV Input Range Range Values 100 %W5W26 W5W26 low Voltage and Milliamp Equivalents for Input 2 Range Values Disconnect the Field WiringPreliminary Information Thermocouple Inputs Using an Ice Bath Input 1 Set Up Wiring 26+ Thermocouple Inputs Using a Thermocouple SourceSet Up Wiring Procedure for RTD Inputs 25R Millivolt or Volt Source 26+ Volt Source 100K pair 26+ Set Up Wiring Procedure for 0 to 10 VoltsSet Up Wiring Procedure for Milliampere Inputs To 10 Volts Preliminary Steps Input 1 Calibration Procedure10 Input 1 Calibration Procedure Numeric Code Lower Display = Cjtemp Upper Display = Aply Lower Display = IN1SPNIf … Then … No connection Input 2 Set Up WiringTo 20 mA or 4 to 20 mA Inputs Input 25+ No connection 26 + Input 2 Calibration ProcedureTo 2 Volts, 0 to 5 Volts, or 1 to 5 Volt Inputs Input 13 Input 2 Calibration Procedure Numeric Code 14 Restore Factory Calibration Restore Input Factory Calibration 150 Output Calibration 19+ Set Up Wiring Procedure for Current OutputCurrent Output Calibration Calibrator Connections Calibrate 100 % Current Output Calibration Procedure Numeric CodeCalibrate 0 % Auxiliary Output Calibration Set Up Wiring Procedure for Auxiliary OutputSet Lock in the Tuning Set Up group to None Upper Display = a Value Auxiliary Output Calibration Procedure Numeric CodeCalibration Mode Lower Display = Auxout Upper Display = SET Lower Display = Tuning Restore Output Factory Calibration ProcedureRestore Factory Calibration Procedure Output Calibration Step Operation Press Result Troubleshooting/Service Troubleshooting Aids 32xx Procedure for Identifying the Software VersionCustomer support Determining the software version Status Tests Power-up Tests Fail Lower Reason for Failure How to Correct the Problem DisplayBackground Tests Background Tests OUT1FL CnferrPV LIM Segerr Display Output Cause Shooting Procedure Controller Failure SymptomsSymptoms Other symptoms Troubleshooting Procedures Troubleshooting Current Output Failure Procedure #1Troubleshooting Power Failure Symptoms Procedure #2 Refer to Section Procedure #3Troubleshooting Three Position Step Control Output Failure Refer to Installation for details Troubleshooting Time Proportional Output Failure Procedure #4 Refer to Output Calibration for details Procedure #5 Refer to Installation for relay contact information Procedure #610 Troubleshooting Alarm Relay Output Failure Refer to Configuration for 11 Troubleshooting a Keyboard Failure Procedure #7 12 Troubleshooting a RS-485 Communications Failure Procedure #8 14 Troubleshooting Auxiliary Output Failure Procedure #913 Troubleshooting an Ethernet Communications Failure Procedure #10 Step What to do Restoring Factory Configuration15 Restoring Factory Configuration 16 Software Upgrades Software Upgrades 176 UDC2500 Exploded View Exploded View Key Part Number Description Software Upgrades see SectionParts Identification Parts Not Shown Removing the chassis Other Modbus Codes Configuration ID TagsGeneral Information Register Count Register Name Access Numbers DecRegister Address Structure Integer Parameter Type Floating Point Parameter Type Byte Count Function Code 20 14h Read Configuration Reference DataDescription Request and Response Formats Register Address Format for Function Code Reference Type DefinitionsFile Number Register Address Example #1 Read Configuration Examples Example #2 Write Restrictions Function Code 21 15h Write Configuration Reference Data Register Format Addresses Dec Hex Unrestricted RegistersRestrictions on Parameter Numbers in One Message Write Configuration Examples Non-volatile Memory Retention General Information Register Addresses Reading Control Data Option Status Read Software Options StatusControl Data Parameters Read SetPoint Program Read Only Information Miscellaneous Read Onlys Register Addresses for Read OnlysSetPoint Program Read Only Information Miscellaneous Read Onlys Setpoint Associated Parameters Setpoint Code SelectionsAssociated Parameters Shed Using a Computer Setpoint Overriding Controller Setpoint1 Shed Timer Reset Computer Setpoint Selection Computer Setpoint Associated Parameters Reading or Writing Configuration ParametersTuning Set-up Group Tuning Lockout 0084 132 10 Set-up Group Setpoint Ramp/Rate SP Ramp/Rate/Program Controller Status 00B4 180 200 11 Set-up Group Accutune 12 Set-up Group Algorithm Algorithm 13 Set-up Group Output Output Algorithms 14 Set-up Group Input Input = NNM H Burnout Open 00A4 164 15 Set-up Group Input Input 00AB 171 16 Set-up Group Control Control = RPM 17 Set-up Group Options Options SP=PV 18 Set-up Group Communications Communications 19 Set-up Group Alarms Alarms Alarm 1 Setpoint 008E 142 INT 20 Set-up Group Display Display Function Code Field Modbus RTU Exception Codes Exception Definition Description Code QueryResponse 21 Modbus RTU Data Layer Status Exception Codes 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