Troubleshooting / Service | Honeywell UDC 3300 manual

Section 9 – Troubleshooting / Service

9.1 Overview

Introduction

Instrument performance can be adversely affected by installation and application problems as well as 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. If a replacement of any part is required, follow the procedures listed under “Parts Replacement Procedures.”

What’s in this section? The following topics are covered in this section.

Topic

See Page

9.1Overview

9.2Troubleshooting Aids

•Overall Error Messages

•Controller Failure Symptoms

•Customer Support

•Determining the Software Version Number

9.3Power-up Tests

9.4Status Tests

9.5Background Tests

9.6Controller Failure Symptoms

9.7Troubleshooting Procedures

•Power Failure

•Current Proportional Output Failure

•Position Proportional Output Failure

•Time Proportional Output Failure

•Time/Current - Current/Time Proportional Output Failure

•Alarm Relay Output Failure

•Keyboard Failure

•Communications Failure

9.8Parts Replacement Procedures

•How to remove the chassis

•How to replace the display/keyboard assembly

•How to remove printed wiring boards from the chassis

•Printed wiring board identification

•2nd input board replacement procedure

•Power input board replacement procedure

•Digital input board replacement procedure

•Aux. output/commun. board replacement procedure

•MCU/output board replacement procedure

9.9Maintenance

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Honeywell UDC 3300 manual Troubleshooting / Service

Contents

51-52-25-55D UDC Universal Digital Controller Product Manual Revision D April Honeywell West Spring Street Freeport, Illinois World Wide Web AbstractReferences Contacts Symbol Definition Symbol Definitions Table of Contents Operation Configuration Prompt Definitions147 205 271 219233 243 DC330X-EE-XXX-X2, DC330X-AA-XXX-X2 Figures Tables 154 246 Xii UDC 3300 Controller Product Manual Offered in a 1/4 DIN size controller Pharmaceuticals, and testing and environmental workConfigurable parameters Introduction UDC 3300 Controller Product Manual Operator Interface Operator Interface Displays and Indicators Loop 1/2 Function of keys OTI KeySPn ToBEGIN UDC 3300 Controller Product Manual Overview Introduction What’s in this section?Topic See Design SpecificationsStray Rejection Common Mode Normal Mode Open Collector Outputs One or Two Current Output IsolatedElectromechanical Relays One or Two Solid State Relays One or Two RTU Power Consumption Power Inrush Current WeightDmcs RS422/485 Ascii RS422/485 Modbus Environmental and Operating Conditions Mechanical ShockVoltage Vdc Voltage Vac 90 to 240 Vac 24 Vac Frequency Hz Model number Model Number Interpretation Physical considerations Overall dimensions DimensionsMounting Controller Refer to -3 and follow the procedure in -2 to mountMounting procedure Step Procedure for Mounting the Controller Action Electrical considerations WiringControl/alarm circuit wiring Electrical Noise Precautions Identify your wiring requirements Shows which wire functions should be bundled togetherPermissible wire bundling Permissible Wiring Bundling Bundle No Wire Functions Controller accordingly Using the information contained in the model number, selectWiring the controller Wiring Requirements Wiring Diagrams Line voltage wiring Controller 4 mm2Due to the voltage drop caused by the in-rush current Volts Milliamps Input #1/Input #2 connectionsThermocouple MV or Volts Except 0-10 Volts 22 + 23 + Two Hlai replace second Llai connectionsHigh Level Analog Input Connections See Below 5V Connections MA Connections Electromechanical Relay Output-Model DC330X-EE-XXX L2/N PowerAlarm Relay #1 Load Time proportional output AC Load Alarm Relay #2 LoadRelay Load Power Alarm Relay #1 Load AC Load 10 10-amp Solid State Relay Output-Model DC330X-SS-XX Time Proportional Simplex Ohms Output or Alarm LoadCurrent output/ universal output connections Controller Load L2/N 16 + Output Type CurrentRelay #1 Connect shield to ground At one end only Position proportional output connectionsCalibration Mechanically linked To motor Digital inputs connections Auxiliary output connectionsAuxiliary Load 1000 Ω Do not mix half Full duplex wiringMaster L2/N TX-/RX Master 120 OhmResistor Configure Voltage at transmitter Zero VAL = Span VAL =+16 26 + 250 ohm Resistor Diode here to reduce Control and Alarm Relay Contact Information Lists the Alarm Relay contact informationLists the Control Relay contact information Prompts Continuous background tests that are being performedIntroduction Topic Configuration Prompts Diagram prompt hierarchyTOT Rate * x = 0 to Input How To Get Started Configuration record sheetParameter explanations or definitions Configuration Tips Configuration Tips Press Configuration ProcedureIntroduction Procedure Configuration Procedure Step Operation Step Operation SET UP Lower Display Function Prompt Loop 1 Tuning Parameters Set Up GroupFactory Setting Function prompts Selections or Range of Setting Disabl EnableFunction Name Loop 2 Tuning Parameters Set Up Group Cascade or Two Loops Tuning Loop 2 Group FunctionFunction Selections or Name Range of Setting Function prompts Function Prompt SP Ramp, SP Rate, or SP Programming Set Up GroupLists all the function prompts in the SP Ramp Set Up group Setpoint rate SEG5RATE SEG6 SP SEG6TIME Recycles Soak DEV Prog END State Keyreset HotstartSEG1RATE SEG2 SP SEG2TIME SEG3RATE SEG4 SP SEG4TIME Accutune Set Up Group Function Selections or Lists the function prompts in the Accutune Set Up groupFactory Refer Setting Accutune Group Function Prompts Algorithm Data Set Up Group Introduction Function promptsAlgorithm Group Function Prompts PCO SEL PCT CO ATM Pres ALG1BIAS INP ALG2 INP ALG1None Math K Calc HI Calc LO ALG1 INA ALG1 INB ALG1 INC ALG2 INC Factory Setting ReferALG2 INA ALG2 INB Totalize Xxxxxxx TOT Scal TOT SEC Rset ? TOT Rate OUT2 ALG Rlystate Output Algorithm Parameters Set Up GroupOutput Algorithm Group Function Prompts OUT ALG Analytic IN1 HI IN1 LO Ratio Input 1 Parameters Set Up GroupInput 1 Group Function Prompts Selections or IN1 Type XMITTER1 None Down Nofs Bias IN1Filter BURNOUT1 Input 2 Parameters Set Up Group Input 3 Group Function Selections or Range of Setting Input 3 Parameters Set Up Group Loop 1 Control Parameters Set Up Group Process12 Control Group Function Prompts Selections or MAN OUT Auto OUT OUT RatePCT/M UP PCT/M DN Dropoff Deadband OUT Hyst Failmode Failsafe Swfail Loop 2 Control Parameters Set Up Group 13 Control 2 Group Function PromptsINP OUT Rate PCT/M UP PCT/M DN OUTHiLIM OUTLoLIM HiLIM I LoLIMDropoff Deadband Failmode Failsafe AUX OUT CUR OUT2 Options Set Up GroupPrompts will not appear Options Group Function Prompts None Disabl DIG1 COM DIG2 COM+DISAT +RUN Duplex Communications Set Up Group15 Communications Group Function Prompts Shedenab Shedtime Parity Baud Last To LSP Percnt Disabl Fsafe To MAN To LSP To CSP Percnt ENG A1S1 VAL A1S2 VAL A2S1 VAL A2S2 VAL Alarms Set Up Group A1S2 H L A1S1TYPE A1S2TYPE A2S1TYPE A2S2TYPEA1S1 H L A1S1 EV A2S2 EV AL Hyst ALM OUT1 Block A2S1 H LA2S1 EV A2S2 H L DECIMAL2 Display Parameters Set Up GroupDisplay Group Function Prompts Decimal Calibration data Calibration Group Elapsed Time Timer Maintenance Set Up GroupOthers, to keep track of maintenance needs Maintenance Group Function Prompts Disabl None Counter Number of Counts Password Reset TypeStatus Group Status test data Keep a record Configuration Record Sheet Value or Selection Factory Setting Group PromptFunction Value or Prompt Selection Expanded Model DC330E-XX-XXX Value or Selection Control CONTROL2 Options UDC 3300 Process Controller Product Manual Configuration Prompt Definitions Parameter Definition Introduction Set this group last Tuning group promptsTuning Group Prompt Definitions Lower Display Upper Display Range of Setting Or Selection Rset MIN Rset RPM MAN Rset PROPBD2 Gain Lower Display Prompt None Calib + Conf + View MAX Disabl Enable Configure Until ALL Configuration is CompleteSecurity Lockout Auto MAN SP SEL RUN Hold Gain PV band over which each Value Gain applies Loop 2 Tuning Parameters Set Up Group Introduction Tuning 2 group promptsLoop 2 Tuning Group Prompt Lower Display Setpoint Ramp/Rate/Programming Set Up Group Introduction SP Ramp/Rate/ Programming group promptsSetpoint Ramp/Rate Group Definitions Lower Display Prompt EU/HR UP EU/HR DN EU/HRUP2 Final SP SP Rate EU/HRDN2 SP Prog Or Selection Accutune Group Definitions Lower Display Prompt Introduction Accutune group prompts Accutune for Loop Demand Tuning Plus PV Adaptive TUNE- SameSetpoint Tuning Plus PV Adaptive TUNE- Same Disabl Tune TUN+PV SP+PV Criteria CRITERA2 KPG SP CHAN2 AT Error AT ERR Read OnlyRuning None Outlim Idfail Abort LOW PV Algorithm Group Definitions Lower Display Prompt Introduction Algorithm group prompts PID a PID B ALG Pidloops3PSTEP Loop 2LOOPS Cascad PID a PID B PD+MR Disabl HI SEL LO SEL Timer Period Start Disp KEY ALARM2 TI REM TimeNone AVG Multiplier with Square ROOT- The following RelhumSummer with Ratio and BIAS- The following Input High Select with Ratio and BIAS- This Math K Calc HI Calc LO Carb B Carb C Carb D FCC DEW PT Oxygen Disabled INP LP1OUT LP2OUT AL1 AL2 None Disabl OnlineFor Example  Mult Lower Display Upper Display Prompt Range of SettingFWR2 FFWDM2 PCT H2 ALG2BIAS Where Flow Sfcm Summary of Flow Values At Values Conditions X2 Input Value X Axis 8SEG CH1X0 Input Value X Axis X1 Input Value X Axis X0 VALU2 Segment Characterizer #2- a second eight Example of Eight Segment Characterizer Totalize Xxxxxxx TOT Scal TOT SEC Rset ? Unlock Lock YESRead only Second Minute Hour DAY ML/DAY Introduction Output algorithm group prompts Output Algorithm Group Definitions Lower Display PromptTime Currnt Positn Time D Other prompts affected 4-20 RNG CUR D CUR TI TI CUR OUT2 ALG Rlystate RLY Type Input 1 Group Definitions Upper Display Parameter Range of Setting DefinitionBias, filter, burnout, and emissivity Input 1 group prompts Lower Display Prompt Resistivity Xmitter AnalyticORP Conductivity IN1 LO Ratio Bias IN1 Filter Burnout EMISSIV1 IN2 Type SlidewireIntroduction Input 2 group prompts Lower Display Prompt Input 2 Group Definitions XMITTER2 IN3 HI IN3 LO Ratio Bias IN3 Filter Introduction Input 3 group prompts Lower Display PromptInput 3 Group Definitions IN3 Type Input Algorithm Introduction Control group prompts Lower Display PromptPV Source PID Sets Input Setpoint Select PID Sets SW Value LSP’S2PV SW 2SP SW Gain S Three Manual LSP RSP RSP SRC Autobias SP Track OUT Rate PCT/M UP For Three Position Step Control OnlySP HiLIM Control Output DIRECTION- Select direct or reverse acting OUT Hyst Failmode Failsafe Swfail Failsafe ModeOUTLoLIM Hi LIM Lo LIM Dropoff PBorGAIN PB PCT GainRPM MIN Input Input Algorithm Force MA PID Sets Introduction Control 2 group prompts11 Control 2 Group Definitions Lower Display Prompt PV 2 SRC Only TWO Three RSP SRC Autobias Sptrack Revrse Disabl Enable OUT HiLIM OUT LoLIMHi LIM Lo LIM 128 UDC 3300 Process Controller Product Manual No Auxiliary Output Selection with desired scalingOption group prompts Lower Display Prompt Options Group Definitions DEV Output LSP AL1 AL2 PV2 OUTPT2 SP L2 AUX OUT CB OUT2 None To MAN To LSP To 2SP To 3SP To DIRNo Digital Input Selections Stop MAN FS PV 2IN PV 3IN Rerun To RUN To RSP RST FB TRACK1 TRACK2 Digital Input 2 Selections DIG DIG 1 COMDIG DIG2 COM Any Digital Input Selection Plus RUN Setpoint Shed Enab Introduction Communications group prompts13 Communications Group Definitions Lower Display Prompt ComSTATE Com Addr ComADDR2 Shedtime Parity Baud Duplex WsfloatEven Parity Percnt ENG Last Toauto FsafeShed SP To LSP To CSP 138 UDC 3300 Process Controller Product Manual Introduction Alarms group prompts 14 Alarms Group Definitions Lower Display PromptA1S1 VAL A1S2 VAL A2S1 VAL Event on SP Programming Event OFF SP Programming No Alarm InputAlarm on Manual Mode Loop 1 Note A1S1TYPE Beginning of Segment END of Segment High Alarm LOW AlarmA1S2TYPE A2S1TYPE A2S2TYPE High LOW Begin END AL Hyst ALM OUT1 Block How to configure alarm to turn on and off with HealthWatch Introduction Display group prompts Lower Display Prompt Display Group DefinitionsDecimal DECIMAL2 Temp Unit PWR Freq Ratio Input Calibration in this manual for complete information Maintenance GroupMaintenance Group Definitions Calibration Data Gsoak Sootng DIGIN1 DIGIN2 MAN2 TIME1 Complete information Failure. Refer to the Troubleshooting in this manual forCOUNTS1 COUNTER2 COUNTS2 COUNTER3 COUNTS3 Password RES Type Status Test Data Operation How to Power Up the Controller Key Pressed Lower Display Keys Procedure for Testing the Displays and Keys Press Until you see Introduction Security code numbers ProcedureStep Procedure for Entering a Security Code Press Action Entering a Security Code Monitoring Your Controller Operator interfaceDecimal point position Automatic Mode MAN-Manual Mode Degrees Fahrenheit Degrees CelsiusAnnunciators Viewing the operating parameters Lower Display Key ParameterBIA Tune OFF Tune RUN Error Messages Description Diagnostic error messages Setpoint Start-up ProcedureStart-up procedure is given in Table Enter the local Remote Setpoint Manual Cascade Automatic Cascade Available modes Mode definitionsOperating Mode Definitions Operating Modes Changing Operating Modes Mode Change What happens when you change modes SP 2SP 3SP RSP CSP Selecting manual or automatic mode Position proportional backup mode Introduction Selecting the local setpoint source Setpoints Hold Changing local setpoint 1, 2, or Setpoint selection indication Enabling or disabling the remote setpoint Setpoint Ramp Rate Configuration Operation SP Ramp Configuring the setpoint ramp Procedure14 Procedure for Configuring a Setpoint Ramp Step Operation Single Setpoint Ramp UDC 3300 Controller Product Manual 165 15 Procedure for Running a Setpoint Ramp Step Operation Running the setpoint ramp Procedure UDC 3300 Controller Product Manual 167 Introduction Select two sets or gain scheduling Using Two Sets of Tuning Constants RSET2 Set switchover valueSet tuning constant values for each set Rate Rset = 1 or Introduction Procedure for displaying the alarm setpoints Alarm Setpoints Loop Two Loops of Control OverviewIntroduction Selections 21 Control Loop Selections Input Input Algorithm Functional overview Loop 1 and Loop 2 of a dual loop controller Override rules Internal cascade Is a block diagram of the Hi/Lo Override Selector Model DC330E-KE-5XX Two-loop restrictions Select the output algorithm for each loop Configuring Two Loops of Control24 Procedure for Selecting 2-loop Algorithm Step Operation 25 Procedure for Selecting Output Algorithm Step Operation Select control parameters for each loop Procedure in -26 shows you how select the 2 loop algorithm Procedure in -27 shows you how select the Tuning Parameters Select tuning parameters for each group27 Procedure for Selecting Tuning Parameters Step Operation Loop Indication IndicatorMonitoring Two Loops of Control 28 Digital Display Indication-Two Loops Operating Two Loops of Control Loop operationOperating modes and setpoint source Keyboard operation Accutune Tune will operate with this algorithm Power-up outputThree Position Step Control Algorithm Three Position Step Control algorithm Loop 1 only allows Introduction Input algorithm selections Input Math Algorithms Segment characterization Totalizer function Xn Value Yn Value Alarm on totalizer value Totalizer reset via digital input Digital Input Option Remote Switching Introduction Action on closure30 Digital Input Option Action on Contact Closure TRACK1 TRACK2 Timer AM STATo RUN Stop MAN FS Action on contact closure Means that the parameter is configured and the actionWill occur when the digital input is active Display Indication Digital Inputs 1 and 2 Combination Action Example Auto/Manual Station Introduction FunctionState DI #1 Open DI #1 Closed Press To Enter Remarks Refer to -33 and set up the controller in the order shownDescription Configuration Up Group Function Prompts Options Step PressUp Group Function Prompts Press To Enter Remarks Value or Selection Algorithm Fuzzy Overshoot Suppression Introduction How it works Configuration Accutune 34 Accutune Rules and Regulations Applicable Rule How Tune demand tuning works34 is a list of rules for Accutune Rules Starting Tune demand tuning 35 Procedure for Starting Tune Demand Tuning Step ActionSwitch to Automatic mode by pressing the MANUAL/AUTO key Setpoint changes Using Tune at start-up for duplex heat/cool MANUAL/AUTO Using SP tuning at start-up37 Procedure for Using SP Tuning at Start-up Step Action SP tuning after start-up Aborting SP tuning Using SP tuning at start-up for duplex heat/cool Key to return to manual mode. This will Values are entered and used until retuning occurs againRetuning Error prompt accessing procedure 39 lists the Accutune error prompts and their definitions Error prompt Upper Display Prompt39 Accutune* Error Prompt Definitions Action to Take Carbon Potential Introduction Features Diagram Carbon Potential ControlUDC HealthWatch When the desired threshold is reachedSee .18 Maintenance for details on using the various HealthWatch maintenance alarms What is programming? Review program data and configuration Fill out the worksheetWhat’s in this section Program Contents UDC 3300 Controller Product Manual 207 Ramp unit Ramp/Soak Profile example Drawing a Ramp/Soak Profile Segment Value Prompt Program Record Sheet Entering the Setpoint Program Data Make sure SP Ramp and SP Rate are disabled firstSetpoint Program Data Entry Procedure Press Result Alarms on the setpoint program Prompt hierarchy Value or Selection use or Prompt Hierarchy and Available Selections SG11RAMP SG11RATE SG12 SP SG12TIME Definition Value or Selection use orSEG2 SP SEG2TIME SEG3RAMP SEG3RATE SEG8 SP SEG8TIME SEG9RAMP SEG9RATE SG10 SP SG10TIME Set the Local Setpoint Run/Monitor the ProgramIntroduction Run/monitor functions Local Setpoint Value # RA Viewing the number of cycles left in the program End Program Power-up state Result/Action Procedures for Changing a Running Setpoint Program Function 218 UDC 3300 Controller Product Manual Introduction What’s in this section Input Calibration IEC Alpha=0.00385 Ohms Ohms low Linear Minimum and Maximum Range ValuesHoneywell Radiamatic Type RH Type RI RTD Disconnect the field wiring Preliminary InformationCalibration steps Equipment Needed Type of Input Equipment needed Input #1, #2, or #3 Set Up Wiring Thermocouple inputs using an ice bathInput Thermocouple inputs using a precision resistor RTD inputs Wiring Connections for RTD Volts only Input Radiamatic, millivolts, or volts except 0 to 10 volts inputs To 10 volt inputs Wiring Connections for 0 to 10 Volt Inputs Copper Leads To 20 mA Source Input 3-Wire terminals as shown belowTo 20 mA inputs 250Ω Resistor Assy From initial value to final 100 % value Input #1, #2, or #3 Calibration ProcedureInput #1, #2, or #3 Calibration Procedure Make sure you have Lockout set to NONE. See Section If… Then… Step Description Action/Result How to restore it ProcedureRestoring Factory Calibration Restoring Factory Calibration Step Operation Step Operation Press Output Calibration Current Proportional Output Calibration Between 0 mA and 21 mAEquipment needed Calibrator connections NONE. See Configuration Make sure Lockout in the Tuning Set Up group is set to Rules for auto mode vs manual mode Displayed values These prompts only appear when position OUT ALG is Procedure for calibrating the Position Proportional outputLockout in Tuning Set Up group is set to NONE. See Section Procedure Do Auto or Do AutoDo MAN Desired span value Lower Display SET UP Set Up Wiring Procedure for Auxiliary Output Step Action Auxiliary Output CalibrationAny other values between 0 mA and 21 mA Value between 0 Auxiliary Output Calibration Procedure Press Action 242 UDC 3300 Controller Product Manual Troubleshooting / Service Installation related problems Application related problemsHardware and software related problems Error Message Prompts Troubleshooting Aids Status Number Test failures Power-up TestsWhat happens at power-up Power-up Tests Upper Display Introduction How to check the status tests Status TestsRAM Test Conf Test CAL Test Fact CRC Pass Status TestsRAM Test Conf CAL Test Fact CRC Fail INP1FAIL INP2FAIL INP3FAIL Background TestsIntroduction Background tests EE Fail RV = INP2 X Ratio + Bias Lower Display Reason for Failure How to Correct the ProblemINP1 RNG INP2 RNG INP3 RNG PV Limit RV Limit PV = INP1 + INP1 Bias Reacting Controller Failure SymptomsCompare your symptoms with those shown in -7 and refer to Troubleshooting procedure indicated to correct the problem How to do it Troubleshooting ProceduresEquipment needed Procedure #1 Troubleshooting Power Failure Symptoms Step What to do Procedure #2 Procedure #3 Procedure #4 Procedure #5 Procedure #6 13 explains how to troubleshoot Alarm Relay Output failure Procedure #7 14 explains how to troubleshoot a Keyboard failure Procedure #8 15 explains how to troubleshoot a Communications failure Introduction Equipment needed Parts Replacement Procedures 16 How to Remove the Chassis Step Action How to remove the chassis How to replace the display/keyboard assembly Refer to -2 and follow the procedure listed in Table 18 Printed Wiring Board Removal from Chassis Step Action How to remove the printed wiring boards from the chassis Prom Printed wiring board identificationOn Digital Input and MCU/Output boards MCU 2nd input board 19 Second Input Board Replacement Procedure Step ActionPower input board 20 Power Input Board Replacement Procedure Step Action Digital input board 21 Digital Input Board Replacement Procedure Step Action Aux.Out/ communications board 23 MCU/Output Board Replacement Procedure Step Action Current Output-P/N Relay Output-P/NMCU/output board Cleaning Maintenance There is a list of parts not shown in Table Exploded View Description Quantity Parts identificationParts not shown Key Part Number Appendix a Manual Tuning Time, Position, or Current Proportional Simplex Control Manual Tuning Procedure for Simplex Control To Reduce Overshoot Manual Tuning Formulas Units Rsetmin or Rsetrpm RSET2MIN or RSETRPM2 Two Sets of Tuning Parameters for Single Output OperationTuning function prompts for HEAT/COOL are PB or Gain Index 278 UDC 3300 Controller Product Manual Y, Z 280 UDC 3300 Controller Product Manual Page Sensing and Control