Troubleshooting Procedures, How to do it | Honeywell UDC 3300

9.7 Troubleshooting Procedures

Introduction	The troubleshooting procedures are listed in numerical order as they
	appear in Table 9-7. 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.

Equipment needed

Procedure #1

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.

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

•DC Milliammeter – mAdc

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

•Voltmeter

Table 9-8 explains how to troubleshoot power failure symptoms.

Table 9-8 Troubleshooting Power Failure Symptoms

Step

1

2

3

4

5

What to do

Check the AC line voltage.

Make sure the chassis plugs into the rear of the case properly.

Check the system for Brown-outs, heavy load switching, etc., and conformance to installation instructions.

Change PS/Input board.

Change MCU/Output board.

How to do it

Use a voltmeter to measure the AC voltage across terminals L1 and L2 on the rear terminal panel of the controller.

Check the earth ground connection.

Withdraw the chassis and visually inspect the controller board and the inside of the case.

Refer to Section 2 - Installation.

Refer to Table 9-20.

Refer to Table 9-23.

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Honeywell UDC 3300 manual Troubleshooting Procedures, Accomplish the task, Equipment needed Procedure #1, How to do it

Contents

51-52-25-55D UDC Universal Digital Controller Product Manual Revision D April Honeywell West Spring Street Freeport, Illinois References AbstractContacts World Wide Web Symbol Definition Symbol Definitions Table of Contents 147 Configuration Prompt Definitions205 Operation 233 219243 271 DC330X-EE-XXX-X2, DC330X-AA-XXX-X2 Figures Tables 154 246 Xii UDC 3300 Controller Product Manual Configurable parameters Pharmaceuticals, and testing and environmental workIntroduction Offered in a 1/4 DIN size controller UDC 3300 Controller Product Manual Operator Interface Operator Interface Displays and Indicators Loop 1/2 Function of keys SPn KeyToBEGIN OTI UDC 3300 Controller Product Manual Introduction What’s in this section? OverviewTopic See Stray Rejection Common Mode SpecificationsNormal Mode Design Electromechanical Relays One or Two Current Output IsolatedSolid State Relays One or Two Open Collector Outputs One or Two Dmcs Power Consumption Power Inrush Current WeightRS422/485 Ascii RS422/485 Modbus RTU Mechanical Shock Environmental and Operating ConditionsVoltage Vdc Voltage Vac 90 to 240 Vac 24 Vac Frequency Hz Model number Model Number Interpretation Dimensions Physical considerations Overall dimensionsMounting Mounting procedure Refer to -3 and follow the procedure in -2 to mountStep Procedure for Mounting the Controller Action Controller Control/alarm circuit wiring WiringElectrical Noise Precautions Electrical considerations Permissible wire bundling Shows which wire functions should be bundled togetherPermissible Wiring Bundling Bundle No Wire Functions Identify your wiring requirements Wiring the controller Using the information contained in the model number, selectWiring Requirements Controller accordingly Wiring Diagrams Controller 4 mm2 Line voltage wiringDue to the voltage drop caused by the in-rush current Thermocouple MV or Volts Input #1/Input #2 connectionsExcept 0-10 Volts Volts Milliamps High Level Analog Input Connections See Below Two Hlai replace second Llai connections5V Connections MA Connections 22 + 23 + Alarm Relay #1 Load L2/N PowerTime proportional output Electromechanical Relay Output-Model DC330X-EE-XXX Relay Load Power Alarm Relay #2 LoadAlarm Relay #1 Load AC Load AC Load 10 10-amp Solid State Relay Output-Model DC330X-SS-XX Time Proportional Simplex Current output/ universal output connections Output or Alarm LoadController Load L2/N Ohms Output Type Current 16 +Relay #1 Calibration Position proportional output connectionsMechanically linked To motor Connect shield to ground At one end only Auxiliary Load Auxiliary output connections1000 Ω Digital inputs connections Master L2/N Full duplex wiringTX-/RX Do not mix half 120 Ohm MasterResistor Configure +16 26 + 250 ohm Resistor Zero VAL = Span VAL =Diode here to reduce Voltage at transmitter Lists the Alarm Relay contact information Control and Alarm Relay Contact InformationLists the Control Relay contact information Introduction Continuous background tests that are being performedTopic Prompts Diagram prompt hierarchy Configuration PromptsTOT Rate * x = 0 to Input Configuration record sheet How To Get StartedParameter explanations or definitions Configuration Tips Configuration Tips Introduction Procedure Configuration ProcedureConfiguration Procedure Step Operation Press Step Operation SET UP Lower Display Factory Setting Loop 1 Tuning Parameters Set Up GroupFunction prompts Function Prompt Disabl Enable Selections or Range of SettingFunction Name Tuning Loop 2 Group Function Loop 2 Tuning Parameters Set Up Group Cascade or Two LoopsFunction Selections or Name Range of Setting Lists all the function prompts in the SP Ramp Set Up group SP Ramp, SP Rate, or SP Programming Set Up GroupSetpoint rate Function prompts Function Prompt SEG1RATE SEG2 SP SEG2TIME Recycles Soak DEV Prog END State Keyreset HotstartSEG3RATE SEG4 SP SEG4TIME SEG5RATE SEG6 SP SEG6TIME Accutune Set Up Group Factory Refer Setting Lists the function prompts in the Accutune Set Up groupAccutune Group Function Prompts Function Selections or Introduction Function prompts Algorithm Data Set Up GroupAlgorithm Group Function Prompts None INP ALG1Math K Calc HI Calc LO ALG1 INA ALG1 INB ALG1 INC PCO SEL PCT CO ATM Pres ALG1BIAS INP ALG2 ALG2 INA Factory Setting ReferALG2 INB ALG2 INC Totalize Xxxxxxx TOT Scal TOT SEC Rset ? TOT Rate Output Algorithm Group Function Prompts Output Algorithm Parameters Set Up GroupOUT ALG OUT2 ALG Rlystate Input 1 Group Function Prompts Selections or Input 1 Parameters Set Up GroupIN1 Type XMITTER1 Analytic IN1 HI IN1 LO Ratio Filter Bias IN1BURNOUT1 None Down Nofs Input 2 Parameters Set Up Group Input 3 Group Function Selections or Range of Setting Input 3 Parameters Set Up Group Process Loop 1 Control Parameters Set Up Group12 Control Group Function Prompts Selections or PCT/M UP PCT/M DN OUT RateDropoff Deadband OUT Hyst Failmode Failsafe Swfail MAN OUT Auto OUT 13 Control 2 Group Function Prompts Loop 2 Control Parameters Set Up GroupINP OUTHiLIM OUTLoLIM HiLIM I LoLIM OUT Rate PCT/M UP PCT/M DNDropoff Deadband Failmode Failsafe Prompts will not appear Options Set Up GroupOptions Group Function Prompts AUX OUT CUR OUT2 +DISAT DIG1 COM DIG2 COM+RUN None Disabl 15 Communications Group Function Prompts Communications Set Up GroupShedenab Shedtime Parity Baud Duplex 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 A1S1 H L A1S1TYPE A1S2TYPE A2S1TYPE A2S2TYPEA1S1 EV A1S2 H L A2S1 EV A2S1 H LA2S2 H L A2S2 EV AL Hyst ALM OUT1 Block Display Group Function Prompts Display Parameters Set Up GroupDecimal DECIMAL2 Calibration data Calibration Group Others, to keep track of maintenance needs Maintenance Set Up GroupMaintenance Group Function Prompts Elapsed Time Timer Status Group Counter Number of Counts Password Reset TypeStatus test data Disabl None Keep a record Configuration Record Sheet Group Prompt Value or Selection Factory SettingFunction Value or Prompt Selection Expanded Model DC330E-XX-XXX Value or Selection Control CONTROL2 Options UDC 3300 Process Controller Product Manual Configuration Prompt Definitions Tuning Group Prompt Definitions Lower Display Introduction Set this group last Tuning group promptsUpper Display Range of Setting Or Selection Parameter Definition Rset MIN Rset RPM MAN Rset PROPBD2 Gain Lower Display Prompt Configure Until ALL Configuration is Complete None Calib + Conf + View MAX Disabl EnableSecurity Lockout Auto MAN SP SEL RUN Hold Gain PV band over which each Value Gain applies Introduction Tuning 2 group prompts Loop 2 Tuning Parameters Set Up GroupLoop 2 Tuning Group Prompt Lower Display Introduction SP Ramp/Rate/ Programming group prompts Setpoint Ramp/Rate/Programming Set Up GroupSetpoint 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 Setpoint Tuning Plus PV Adaptive TUNE- Same Demand Tuning Plus PV Adaptive TUNE- SameDisabl Tune TUN+PV SP+PV Accutune for Loop Criteria CRITERA2 KPG SP CHAN2 Read Only AT Error AT ERRRuning None Outlim Idfail Abort LOW PV Algorithm Group Definitions Lower Display Prompt Introduction Algorithm group prompts PID a PID B Pidloops ALG3PSTEP Loop 2LOOPS Cascad PID a PID B PD+MR Disabl HI SEL LO SEL KEY ALARM2 TI REM Time Timer Period Start DispNone AVG Summer with Ratio and BIAS- The following RelhumInput High Select with Ratio and BIAS- This Multiplier with Square ROOT- The following Math K Calc HI Calc LO Carb B Carb C Carb D FCC DEW PT Oxygen INP LP1OUT LP2OUT AL1 AL2 None Disabl Online DisabledFor Example FWR2 Lower Display Upper Display Prompt Range of SettingFFWDM2  Mult PCT H2 ALG2BIAS Where Flow Sfcm Summary of Flow Values At Values Conditions X0 Input Value X Axis 8SEG CH1X1 Input Value X Axis X2 Input Value X Axis X0 VALU2 Segment Characterizer #2- a second eight Example of Eight Segment Characterizer Unlock Lock YES Totalize Xxxxxxx TOT Scal TOT SEC Rset ?Read only Second Minute Hour DAY ML/DAY Output Algorithm Group Definitions Lower Display Prompt Introduction Output algorithm group promptsTime Currnt Positn Time D Other prompts affected 4-20 RNG CUR D CUR TI TI CUR OUT2 ALG Rlystate RLY Type Bias, filter, burnout, and emissivity Upper Display Parameter Range of Setting DefinitionInput 1 group prompts Lower Display Prompt Input 1 Group Definitions ORP Xmitter AnalyticConductivity Resistivity IN1 LO Ratio Bias IN1 Filter Burnout EMISSIV1 Introduction Input 2 group prompts Lower Display Prompt SlidewireInput 2 Group Definitions IN2 Type Input 3 Group Definitions Introduction Input 3 group prompts Lower Display PromptIN3 Type XMITTER2 IN3 HI IN3 LO Ratio Bias IN3 Filter PV Source PID Sets Introduction Control group prompts Lower Display PromptInput Input Algorithm 2PV SW 2SP SW Gain S PID Sets SW Value LSP’SThree Setpoint Select Manual LSP RSP RSP SRC Autobias SP Track SP HiLIM For Three Position Step Control OnlyControl Output DIRECTION- Select direct or reverse acting OUT Rate PCT/M UP OUTLoLIM Hi LIM Lo LIM Failsafe ModeDropoff OUT Hyst Failmode Failsafe Swfail PB PCT Gain PBorGAINRPM MIN 11 Control 2 Group Definitions Lower Display Prompt Introduction Control 2 group promptsPV 2 SRC Input Input Algorithm Force MA PID Sets Only TWO Three RSP SRC Autobias Sptrack OUT HiLIM OUT LoLIM Revrse Disabl EnableHi LIM Lo LIM 128 UDC 3300 Process Controller Product Manual Option group prompts Lower Display Prompt Selection with desired scalingOptions Group Definitions No Auxiliary Output DEV Output LSP AL1 AL2 PV2 OUTPT2 SP L2 AUX OUT None To MAN To LSP To 2SP To 3SP To DIR CB OUT2No Digital Input Selections Stop MAN FS PV 2IN PV 3IN Rerun To RUN To RSP RST FB TRACK1 TRACK2 DIG DIG2 COM DIG DIG 1 COMAny Digital Input Selection Plus RUN Setpoint Digital Input 2 Selections 13 Communications Group Definitions Lower Display Prompt Introduction Communications group promptsComSTATE Com Addr ComADDR2 Shed Enab Wsfloat Shedtime Parity Baud DuplexEven Parity Shed SP Last Toauto FsafeTo LSP To CSP Percnt ENG 138 UDC 3300 Process Controller Product Manual 14 Alarms Group Definitions Lower Display Prompt Introduction Alarms group promptsA1S1 VAL A1S2 VAL A2S1 VAL Alarm on Manual Mode Loop 1 Note No Alarm InputA1S1TYPE Event on SP Programming Event OFF SP Programming A1S2TYPE A2S1TYPE A2S2TYPE High Alarm LOW AlarmHigh LOW Begin END Beginning of Segment END of Segment AL Hyst ALM OUT1 Block How to configure alarm to turn on and off with HealthWatch Display Group Definitions Introduction Display group prompts Lower Display PromptDecimal DECIMAL2 Temp Unit PWR Freq Ratio Maintenance Group Definitions Maintenance GroupCalibration Data Input Calibration in this manual for complete information Gsoak Sootng DIGIN1 DIGIN2 MAN2 TIME1 COUNTS1 COUNTER2 COUNTS2 COUNTER3 COUNTS3 Password RES Type Failure. Refer to the Troubleshooting in this manual forStatus Test Data Complete information Operation How to Power Up the Controller Key Pressed Lower Display Keys Procedure for Testing the Displays and Keys Press Step Procedure for Entering a Security Code Press Action Introduction Security code numbers ProcedureEntering a Security Code Until you see Operator interface Monitoring Your ControllerDecimal point position Degrees Fahrenheit Degrees Celsius Automatic Mode MAN-Manual ModeAnnunciators Lower Display Key Parameter Viewing the operating parametersBIA Tune OFF Tune RUN Error Messages Description Diagnostic error messages Start-up procedure is given in Table Start-up ProcedureEnter the local Setpoint Operating Mode Definitions Available modes Mode definitionsOperating Modes Remote Setpoint Manual Cascade Automatic Cascade 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 14 Procedure for Configuring a Setpoint Ramp Step Operation Configuring the setpoint ramp ProcedureSingle Setpoint Ramp SP 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 Set tuning constant values for each set Set switchover valueRate Rset RSET2 = 1 or Introduction Procedure for displaying the alarm setpoints Alarm Setpoints Introduction Selections Two Loops of Control Overview21 Control Loop Selections Input Input Algorithm Loop 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 24 Procedure for Selecting 2-loop Algorithm Step Operation Configuring Two Loops of Control25 Procedure for Selecting Output Algorithm Step Operation Select the output algorithm for each loop Select control parameters for each loop Procedure in -26 shows you how select the 2 loop algorithm Select tuning parameters for each group Procedure in -27 shows you how select the Tuning Parameters27 Procedure for Selecting Tuning Parameters Step Operation Monitoring Two Loops of Control Indicator28 Digital Display Indication-Two Loops Loop Indication Loop operation Operating Two Loops of ControlOperating modes and setpoint source Keyboard operation Three Position Step Control Algorithm Power-up outputThree Position Step Control algorithm Loop 1 only allows Accutune Tune will operate with this algorithm Introduction Input algorithm selections Input Math Algorithms Segment characterization Totalizer function Xn Value Yn Value Alarm on totalizer value Totalizer reset via digital input Introduction Action on closure Digital Input Option Remote Switching30 Digital Input Option Action on Contact Closure To RUN Timer AM STAStop MAN FS TRACK1 TRACK2 Will occur when the digital input is active Means that the parameter is configured and the actionDisplay Indication Action on contact closure Digital Inputs 1 and 2 Combination Action Example Introduction Function Auto/Manual StationState DI #1 Open DI #1 Closed Description Configuration Refer to -33 and set up the controller in the order shownUp Group Function Prompts Press To Enter Remarks Up Group Function Prompts Press To Enter Remarks Step PressValue or Selection Algorithm Options Fuzzy Overshoot Suppression Introduction How it works Configuration Accutune 34 is a list of rules for Accutune How Tune demand tuning worksRules 34 Accutune Rules and Regulations Applicable Rule 35 Procedure for Starting Tune Demand Tuning Step Action Starting Tune demand tuningSwitch to Automatic mode by pressing the MANUAL/AUTO key Setpoint changes Using Tune at start-up for duplex heat/cool 37 Procedure for Using SP Tuning at Start-up Using SP tuning at start-upStep Action MANUAL/AUTO SP tuning after start-up Aborting SP tuning Using SP tuning at start-up for duplex heat/cool Retuning Values are entered and used until retuning occurs againError prompt accessing procedure Key to return to manual mode. This will Error prompt Upper Display Prompt 39 lists the Accutune error prompts and their definitions39 Accutune* Error Prompt Definitions Action to Take Carbon Potential Introduction Features Carbon Potential Control DiagramUDC See .18 Maintenance for details on using the various When the desired threshold is reachedHealthWatch maintenance alarms HealthWatch Fill out the worksheet What is programming? Review program data and configurationWhat’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 Setpoint Program Data Entry Procedure Press Result Make sure SP Ramp and SP Rate are disabled firstAlarms on the setpoint program Prompt hierarchy Entering the Setpoint Program Data Value or Selection use or Prompt Hierarchy and Available Selections SEG2 SP SEG2TIME SEG3RAMP SEG3RATE Definition Value or Selection use orSEG8 SP SEG8TIME SEG9RAMP SEG9RATE SG10 SP SG10TIME SG11RAMP SG11RATE SG12 SP SG12TIME Introduction Run/monitor functions Run/Monitor the ProgramLocal Setpoint Value Set the Local Setpoint # 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 Honeywell Radiamatic Type RH Type RI Minimum and Maximum Range ValuesRTD IEC Alpha=0.00385 Ohms Ohms low Linear Preliminary Information Disconnect the field wiringCalibration steps Equipment Needed Type of Input Equipment needed Thermocouple inputs using an ice bath Input #1, #2, or #3 Set Up WiringInput 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 To 20 mA inputs Input 3-Wire terminals as shown below250Ω 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 If… Then… Step Description Restoring Factory Calibration How to restore it ProcedureRestoring Factory Calibration Step Operation Action/Result Step Operation Press Output Calibration Between 0 mA and 21 mA Current Proportional Output CalibrationEquipment 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 Lockout in Tuning Set Up group is set to NONE. See Section Procedure for calibrating the Position Proportional outputProcedure These prompts only appear when position OUT ALG is Do Auto Do Auto orDo MAN Desired span value Lower Display SET UP Auxiliary Output Calibration Set Up Wiring Procedure for Auxiliary Output Step ActionAny 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 Application related problems Installation related problemsHardware and software related problems Error Message Prompts Troubleshooting Aids Status Number What happens at power-up Power-up TestsPower-up Tests Upper Display Test failures Status Tests Introduction How to check the status testsRAM Test Conf Test CAL Test Fact CRC RAM Test Conf CAL Test Fact CRC Status TestsFail Pass Introduction Background tests Background TestsEE Fail INP1FAIL INP2FAIL INP3FAIL INP1 RNG INP2 RNG INP3 RNG PV Limit RV Limit Lower Display Reason for Failure How to Correct the ProblemPV = INP1 + INP1 Bias RV = INP2 X Ratio + Bias Compare your symptoms with those shown in -7 and refer to Controller Failure SymptomsTroubleshooting procedure indicated to correct the problem Reacting Equipment needed Procedure #1 Troubleshooting ProceduresTroubleshooting Power Failure Symptoms Step What to do How to do it 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 On Digital Input and MCU/Output boards Printed wiring board identificationMCU Prom Power input board 19 Second Input Board Replacement Procedure Step Action20 Power Input Board Replacement Procedure Step Action 2nd input board Digital input board 21 Digital Input Board Replacement Procedure Step Action Aux.Out/ communications board Current Output-P/N Relay Output-P/N 23 MCU/Output Board Replacement Procedure Step ActionMCU/output board Cleaning Maintenance There is a list of parts not shown in Table Exploded View Parts not shown Parts identificationKey Part Number Description Quantity Appendix a Manual Tuning Time, Position, or Current Proportional Simplex Control Manual Tuning Procedure for Simplex Control To Reduce Overshoot Manual Tuning Formulas Units Tuning function prompts for HEAT/COOL are Two Sets of Tuning Parameters for Single Output OperationPB 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