Controller Failure Symptoms, Reacting | Honeywell UDC 3300 guide

9.6 Controller Failure Symptoms

Introduction	In addition to the error message prompts, there are failure symptoms that
	can be identified by noting how the controller displays and indicators are
	reacting.
Symptoms	Compare your symptoms with those shown in Table 9-7 and refer to the
	troubleshooting procedure indicated to correct the problem.
	Table 9-7	Controller Failure Symptoms

Upper	Lower	Indicators	Controller	Probable
Display	Display		Output	Cause

Trouble- shooting Procedure

Blank

OK

OK

OK

OK

OK

Blank

Displayed

Output

disagrees

with Controller

Output

OK

Off

OK

OK

OK

OK

OK

None

Controller

Output

disagrees

with Displayed

Output

External Alarm function does not operate properly

Power Failure

Current

Proportional

Output

Position

Proportional

Output

Time Proportional

Output

Current/Time

Proportional

Output

Malfunction in alarm output

1

2

3

4

5

6

Display does not function when a key is pressed

Controller fails to go into “Slave” operation during communications

Keyboard

Malfunction

Communications

Failure

7

8

Other symptoms

If a set of symptoms or prompts other than the one you started with appears while troubleshooting, re-evaluate the symptoms. This may lead to a different troubleshooting procedure.

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.

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Honeywell UDC 3300 manual Controller Failure Symptoms, Reacting, Compare your symptoms with those shown in -7 and refer to

Contents

UDC Universal Digital Controller Product Manual 51-52-25-55D Honeywell West Spring Street Freeport, Illinois Revision D April Abstract ReferencesContacts World Wide Web Symbol Definitions Symbol Definition Table of Contents Configuration Prompt Definitions 147205 Operation 219 233243 271 Figures DC330X-EE-XXX-X2, DC330X-AA-XXX-X2 Tables 154 246 Xii UDC 3300 Controller Product Manual Pharmaceuticals, and testing and environmental work Configurable parametersIntroduction Offered in a 1/4 DIN size controller UDC 3300 Controller Product Manual Operator Interface Displays and Indicators Operator Interface Function of keys Loop 1/2 Key SPnToBEGIN OTI UDC 3300 Controller Product Manual Overview Introduction What’s in this section?Topic See Specifications Stray Rejection Common ModeNormal Mode Design Current Output Isolated Electromechanical Relays One or TwoSolid State Relays One or Two Open Collector Outputs One or Two Power Consumption Power Inrush Current Weight DmcsRS422/485 Ascii RS422/485 Modbus RTU Environmental and Operating Conditions Mechanical ShockVoltage Vdc Voltage Vac 90 to 240 Vac 24 Vac Frequency Hz Model Number Interpretation Model number Physical considerations Overall dimensions DimensionsMounting Refer to -3 and follow the procedure in -2 to mount Mounting procedureStep Procedure for Mounting the Controller Action Controller Wiring Control/alarm circuit wiringElectrical Noise Precautions Electrical considerations Shows which wire functions should be bundled together Permissible wire bundlingPermissible Wiring Bundling Bundle No Wire Functions Identify your wiring requirements Using the information contained in the model number, select Wiring the controllerWiring Requirements Controller accordingly Wiring Diagrams Line voltage wiring Controller 4 mm2Due to the voltage drop caused by the in-rush current Input #1/Input #2 connections Thermocouple MV or VoltsExcept 0-10 Volts Volts Milliamps Two Hlai replace second Llai connections High Level Analog Input Connections See Below5V Connections MA Connections 22 + 23 + L2/N Power Alarm Relay #1 LoadTime proportional output Electromechanical Relay Output-Model DC330X-EE-XXX Alarm Relay #2 Load Relay Load PowerAlarm Relay #1 Load AC Load AC Load 10 10-amp Solid State Relay Output-Model DC330X-SS-XX Time Proportional Simplex Output or Alarm Load Current output/ universal output connectionsController Load L2/N Ohms 16 + Output Type CurrentRelay #1 Position proportional output connections CalibrationMechanically linked To motor Connect shield to ground At one end only Auxiliary output connections Auxiliary Load1000 Ω Digital inputs connections Full duplex wiring Master L2/NTX-/RX Do not mix half Master 120 OhmResistor Configure Zero VAL = Span VAL = +16 26 + 250 ohm ResistorDiode here to reduce Voltage at transmitter Control and Alarm Relay Contact Information Lists the Alarm Relay contact informationLists the Control Relay contact information Continuous background tests that are being performed IntroductionTopic Prompts Configuration Prompts Diagram prompt hierarchyTOT Rate * x = 0 to Input How To Get Started Configuration record sheetParameter explanations or definitions Configuration Tips Configuration Tips Configuration Procedure Introduction ProcedureConfiguration Procedure Step Operation Press SET UP Lower Display Step Operation Loop 1 Tuning Parameters Set Up Group Factory SettingFunction prompts Function Prompt 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 SP Ramp, SP Rate, or SP Programming Set Up Group Lists all the function prompts in the SP Ramp Set Up groupSetpoint rate Function prompts Function Prompt Recycles Soak DEV Prog END State Keyreset Hotstart SEG1RATE SEG2 SP SEG2TIMESEG3RATE SEG4 SP SEG4TIME SEG5RATE SEG6 SP SEG6TIME Accutune Set Up Group Lists the function prompts in the Accutune Set Up group Factory Refer SettingAccutune Group Function Prompts Function Selections or Algorithm Data Set Up Group Introduction Function promptsAlgorithm Group Function Prompts INP ALG1 NoneMath K Calc HI Calc LO ALG1 INA ALG1 INB ALG1 INC PCO SEL PCT CO ATM Pres ALG1BIAS INP ALG2 Factory Setting Refer ALG2 INAALG2 INB ALG2 INC Totalize Xxxxxxx TOT Scal TOT SEC Rset ? TOT Rate Output Algorithm Parameters Set Up Group Output Algorithm Group Function PromptsOUT ALG OUT2 ALG Rlystate Input 1 Parameters Set Up Group Input 1 Group Function Prompts Selections orIN1 Type XMITTER1 Analytic IN1 HI IN1 LO Ratio Bias IN1 FilterBURNOUT1 None Down Nofs Input 2 Parameters Set Up Group Input 3 Parameters Set Up Group Input 3 Group Function Selections or Range of Setting Loop 1 Control Parameters Set Up Group Process12 Control Group Function Prompts Selections or OUT Rate PCT/M UP PCT/M DNDropoff Deadband OUT Hyst Failmode Failsafe Swfail MAN OUT Auto OUT 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 Options Set Up Group Prompts will not appearOptions Group Function Prompts AUX OUT CUR OUT2 DIG1 COM DIG2 COM +DISAT+RUN None Disabl Communications Set Up Group 15 Communications Group Function PromptsShedenab Shedtime Parity Baud Duplex Fsafe To MAN To LSP To CSP Percnt ENG Last To LSP Percnt Disabl Alarms Set Up Group A1S1 VAL A1S2 VAL A2S1 VAL A2S2 VAL A1S1TYPE A1S2TYPE A2S1TYPE A2S2TYPE A1S1 H LA1S1 EV A1S2 H L A2S1 H L A2S1 EVA2S2 H L A2S2 EV AL Hyst ALM OUT1 Block Display Parameters Set Up Group Display Group Function PromptsDecimal DECIMAL2 Calibration Group Calibration data Maintenance Set Up Group Others, to keep track of maintenance needsMaintenance Group Function Prompts Elapsed Time Timer Counter Number of Counts Password Reset Type Status GroupStatus test data Disabl None Configuration Record Sheet Keep a record 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 Introduction Set this group last Tuning group prompts Tuning Group Prompt Definitions Lower DisplayUpper Display Range of Setting Or Selection Parameter Definition Lower Display Prompt Rset MIN Rset RPM MAN Rset PROPBD2 Gain 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 Final SP SP Rate EU/HR UP EU/HR DN EU/HRUP2 Or Selection EU/HRDN2 SP Prog Introduction Accutune group prompts Accutune Group Definitions Lower Display Prompt Demand Tuning Plus PV Adaptive TUNE- Same Setpoint Tuning Plus PV Adaptive TUNE- SameDisabl Tune TUN+PV SP+PV Accutune for Loop KPG SP CHAN2 Criteria CRITERA2 AT Error AT ERR Read OnlyRuning None Outlim Idfail Abort LOW PV Introduction Algorithm group prompts Algorithm Group Definitions Lower Display Prompt 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 Relhum Summer with Ratio and BIAS- The followingInput High Select with Ratio and BIAS- This Multiplier with Square ROOT- The following Carb B Carb C Carb D FCC DEW PT Oxygen Math K Calc HI Calc LO Disabled INP LP1OUT LP2OUT AL1 AL2 None Disabl OnlineFor Example Lower Display Upper Display Prompt Range of Setting FWR2FFWDM2  Mult PCT H2 ALG2BIAS Where Summary of Flow Values At Values Conditions Flow Sfcm 8SEG CH1 X0 Input Value X AxisX1 Input Value X Axis X2 Input Value X Axis Segment Characterizer #2- a second eight X0 VALU2 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 CUR D CUR TI TI CUR Other prompts affected 4-20 RNG OUT2 ALG Rlystate RLY Type Upper Display Parameter Range of Setting Definition Bias, filter, burnout, and emissivityInput 1 group prompts Lower Display Prompt Input 1 Group Definitions Xmitter Analytic ORPConductivity Resistivity IN1 LO Ratio Bias IN1 Filter Burnout EMISSIV1 Slidewire Introduction Input 2 group prompts Lower Display PromptInput 2 Group Definitions IN2 Type Introduction Input 3 group prompts Lower Display Prompt Input 3 Group DefinitionsIN3 Type XMITTER2 IN3 HI IN3 LO Ratio Bias IN3 Filter Introduction Control group prompts Lower Display Prompt PV Source PID SetsInput Input Algorithm PID Sets SW Value LSP’S 2PV SW 2SP SW Gain SThree Setpoint Select RSP SRC Autobias SP Track Manual LSP RSP For Three Position Step Control Only SP HiLIMControl Output DIRECTION- Select direct or reverse acting OUT Rate PCT/M UP Failsafe Mode OUTLoLIM Hi LIM Lo LIMDropoff OUT Hyst Failmode Failsafe Swfail PBorGAIN PB PCT GainRPM MIN Introduction Control 2 group prompts 11 Control 2 Group Definitions Lower Display PromptPV 2 SRC Input Input Algorithm Force MA PID Sets Only TWO Three RSP SRC Autobias Sptrack Revrse Disabl Enable OUT HiLIM OUT LoLIMHi LIM Lo LIM 128 UDC 3300 Process Controller Product Manual Selection with desired scaling Option group prompts Lower Display PromptOptions Group Definitions No Auxiliary Output AUX OUT DEV Output LSP AL1 AL2 PV2 OUTPT2 SP L2 CB OUT2 None To MAN To LSP To 2SP To 3SP To DIRNo Digital Input Selections PV 2IN PV 3IN Rerun To RUN Stop MAN FS TRACK1 TRACK2 To RSP RST FB DIG DIG 1 COM DIG DIG2 COMAny Digital Input Selection Plus RUN Setpoint Digital Input 2 Selections Introduction Communications group prompts 13 Communications Group Definitions Lower Display PromptComSTATE Com Addr ComADDR2 Shed Enab Shedtime Parity Baud Duplex WsfloatEven Parity Last Toauto Fsafe Shed SPTo LSP To CSP Percnt ENG 138 UDC 3300 Process Controller Product Manual Introduction Alarms group prompts 14 Alarms Group Definitions Lower Display PromptA1S1 VAL A1S2 VAL A2S1 VAL No Alarm Input Alarm on Manual Mode Loop 1 NoteA1S1TYPE Event on SP Programming Event OFF SP Programming High Alarm LOW Alarm A1S2TYPE A2S1TYPE A2S2TYPEHigh LOW Begin END Beginning of Segment END of Segment How to configure alarm to turn on and off with HealthWatch AL Hyst ALM OUT1 Block Introduction Display group prompts Lower Display Prompt Display Group DefinitionsDecimal DECIMAL2 Temp Unit PWR Freq Ratio Maintenance Group Maintenance Group DefinitionsCalibration Data Input Calibration in this manual for complete information TIME1 Gsoak Sootng DIGIN1 DIGIN2 MAN2 Failure. Refer to the Troubleshooting in this manual for COUNTS1 COUNTER2 COUNTS2 COUNTER3 COUNTS3 Password RES TypeStatus Test Data Complete information Operation How to Power Up the Controller Keys Procedure for Testing the Displays and Keys Press Key Pressed Lower Display Introduction Security code numbers Procedure Step Procedure for Entering a Security Code Press ActionEntering a Security Code Until you see 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 Diagnostic error messages Error Messages Description Start-up Procedure Start-up procedure is given in TableEnter the local Setpoint Available modes Mode definitions Operating Mode DefinitionsOperating Modes Remote Setpoint Manual Cascade Automatic Cascade What happens when you change modes Changing Operating Modes Mode Change Selecting manual or automatic mode SP 2SP 3SP RSP CSP Position proportional backup mode Setpoints Introduction Selecting the local setpoint source Changing local setpoint 1, 2, or Hold Enabling or disabling the remote setpoint Setpoint selection indication Configuration Operation Setpoint Ramp Rate Configuring the setpoint ramp Procedure 14 Procedure for Configuring a Setpoint Ramp Step OperationSingle Setpoint Ramp SP Ramp UDC 3300 Controller Product Manual 165 Running the setpoint ramp Procedure 15 Procedure for Running a Setpoint Ramp Step Operation UDC 3300 Controller Product Manual 167 Using Two Sets of Tuning Constants Introduction Select two sets or gain scheduling Set switchover value Set tuning constant values for each setRate Rset RSET2 = 1 or Alarm Setpoints Introduction Procedure for displaying the alarm setpoints Two Loops of Control Overview Introduction Selections21 Control Loop Selections Input Input Algorithm Loop Loop 1 and Loop 2 of a dual loop controller Functional overview Internal cascade Override rules Is a block diagram of the Hi/Lo Override Selector Two-loop restrictions Model DC330E-KE-5XX Configuring Two Loops of Control 24 Procedure for Selecting 2-loop Algorithm Step Operation25 Procedure for Selecting Output Algorithm Step Operation Select the output algorithm for each loop Procedure in -26 shows you how select the 2 loop algorithm Select control parameters for each loop Procedure in -27 shows you how select the Tuning Parameters Select tuning parameters for each group27 Procedure for Selecting Tuning Parameters Step Operation Indicator Monitoring Two Loops of Control28 Digital Display Indication-Two Loops Loop Indication Operating Two Loops of Control Loop operationOperating modes and setpoint source Keyboard operation Power-up output Three Position Step Control AlgorithmThree Position Step Control algorithm Loop 1 only allows Accutune Tune will operate with this algorithm Input Math Algorithms Introduction Input algorithm selections Xn Value Yn Value Segment characterization Totalizer function 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 Timer AM STA To RUNStop MAN FS TRACK1 TRACK2 Means that the parameter is configured and the action Will occur when the digital input is activeDisplay Indication Action on contact closure Digital Inputs 1 and 2 Combination Action Example Auto/Manual Station Introduction FunctionState DI #1 Open DI #1 Closed Refer to -33 and set up the controller in the order shown Description ConfigurationUp Group Function Prompts Press To Enter Remarks Step Press Up Group Function Prompts Press To Enter RemarksValue or Selection Algorithm Options Introduction How it works Configuration Fuzzy Overshoot Suppression Accutune How Tune demand tuning works 34 is a list of rules for AccutuneRules 34 Accutune Rules and Regulations Applicable Rule Starting Tune demand tuning 35 Procedure for Starting Tune Demand Tuning Step ActionSwitch to Automatic mode by pressing the MANUAL/AUTO key Using Tune at start-up for duplex heat/cool Setpoint changes Using SP tuning at start-up 37 Procedure for Using SP Tuning at Start-upStep Action MANUAL/AUTO Using SP tuning at start-up for duplex heat/cool SP tuning after start-up Aborting SP tuning Values are entered and used until retuning occurs again RetuningError prompt accessing procedure Key to return to manual mode. This will 39 lists the Accutune error prompts and their definitions Error prompt Upper Display Prompt39 Accutune* Error Prompt Definitions Action to Take Introduction Features Carbon Potential Diagram Carbon Potential ControlUDC When the desired threshold is reached See .18 Maintenance for details on using the variousHealthWatch maintenance alarms HealthWatch 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 Drawing a Ramp/Soak Profile Ramp/Soak Profile example Program Record Sheet Segment Value Prompt Make sure SP Ramp and SP Rate are disabled first Setpoint Program Data Entry Procedure Press ResultAlarms on the setpoint program Prompt hierarchy Entering the Setpoint Program Data Prompt Hierarchy and Available Selections Value or Selection use or Definition Value or Selection use or SEG2 SP SEG2TIME SEG3RAMP SEG3RATESEG8 SP SEG8TIME SEG9RAMP SEG9RATE SG10 SP SG10TIME SG11RAMP SG11RATE SG12 SP SG12TIME Run/Monitor the Program Introduction Run/monitor functionsLocal Setpoint Value Set the Local Setpoint # RA Power-up state Viewing the number of cycles left in the program End Program Procedures for Changing a Running Setpoint Program Function Result/Action 218 UDC 3300 Controller Product Manual Input Calibration Introduction What’s in this section Minimum and Maximum Range Values Honeywell Radiamatic Type RH Type RIRTD IEC Alpha=0.00385 Ohms Ohms low Linear Disconnect the field wiring Preliminary InformationCalibration steps Equipment needed Equipment Needed Type of Input Input #1, #2, or #3 Set Up Wiring Thermocouple inputs using an ice bathInput Thermocouple inputs using a precision resistor Wiring Connections for RTD RTD inputs Radiamatic, millivolts, or volts except 0 to 10 volts inputs Volts only Input Wiring Connections for 0 to 10 Volt Inputs To 10 volt inputs Input 3-Wire terminals as shown below To 20 mA inputs250Ω Resistor Assy Copper Leads To 20 mA Source Input #1, #2, or #3 Calibration Procedure Input #1, #2, or #3 Calibration ProcedureMake sure you have Lockout set to NONE. See Section From initial value to final 100 % value Step Description If… Then… How to restore it Procedure Restoring Factory CalibrationRestoring Factory Calibration Step Operation Action/Result Step Operation Press Output Calibration Current Proportional Output Calibration Between 0 mA and 21 mAEquipment needed Calibrator connections Make sure Lockout in the Tuning Set Up group is set to NONE. See Configuration Rules for auto mode vs manual mode Displayed values Procedure for calibrating the Position Proportional output Lockout in Tuning Set Up group is set to NONE. See SectionProcedure These prompts only appear when position OUT ALG is Do Auto or Do AutoDo MAN Lower Display SET UP Desired span value Set Up Wiring Procedure for Auxiliary Output Step Action Auxiliary Output CalibrationAny other values between 0 mA and 21 mA Auxiliary Output Calibration Procedure Press Action Value between 0 242 UDC 3300 Controller Product Manual Troubleshooting / Service Installation related problems Application related problemsHardware and software related problems Troubleshooting Aids Error Message Prompts Number Status Power-up Tests What happens at power-upPower-up Tests Upper Display Test failures Introduction How to check the status tests Status TestsRAM Test Conf Test CAL Test Fact CRC Status Tests RAM Test Conf CAL Test Fact CRCFail Pass Background Tests Introduction Background testsEE Fail INP1FAIL INP2FAIL INP3FAIL Lower Display Reason for Failure How to Correct the Problem INP1 RNG INP2 RNG INP3 RNG PV Limit RV LimitPV = INP1 + INP1 Bias RV = INP2 X Ratio + Bias Controller Failure Symptoms Compare your symptoms with those shown in -7 and refer toTroubleshooting procedure indicated to correct the problem Reacting Troubleshooting Procedures Equipment needed Procedure #1Troubleshooting Power Failure Symptoms Step What to do How to do it Procedure #2 Procedure #3 Procedure #4 Procedure #5 13 explains how to troubleshoot Alarm Relay Output failure Procedure #6 14 explains how to troubleshoot a Keyboard failure Procedure #7 15 explains how to troubleshoot a Communications failure Procedure #8 Parts Replacement Procedures Introduction Equipment needed How to remove the chassis 16 How to Remove the Chassis Step Action Refer to -2 and follow the procedure listed in Table How to replace the display/keyboard assembly How to remove the printed wiring boards from the chassis 18 Printed Wiring Board Removal from Chassis Step Action Printed wiring board identification On Digital Input and MCU/Output boardsMCU Prom 19 Second Input Board Replacement Procedure Step Action Power input board20 Power Input Board Replacement Procedure Step Action 2nd input board 21 Digital Input Board Replacement Procedure Step Action Digital input board Aux.Out/ communications board 23 MCU/Output Board Replacement Procedure Step Action Current Output-P/N Relay Output-P/NMCU/output board Maintenance Cleaning Exploded View There is a list of parts not shown in Table Parts identification Parts not shownKey Part Number Description Quantity Appendix a Manual Tuning Manual Tuning Procedure for Simplex Control Time, Position, or Current Proportional Simplex Control Manual Tuning Formulas Units To Reduce Overshoot Two Sets of Tuning Parameters for Single Output Operation Tuning function prompts for HEAT/COOL arePB or Gain Rsetmin or Rsetrpm RSET2MIN or RSETRPM2 Index 278 UDC 3300 Controller Product Manual Y, Z 280 UDC 3300 Controller Product Manual Page Sensing and Control