UDC 3300 Process Controller Product Manual

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Honeywell manual UDC 3300 Process Controller Product Manual

Contents

UDC Universal Digital Controller Product Manual 51-52-25-55D Honeywell West Spring Street Freeport, Illinois Revision D April Contacts AbstractReferences World Wide Web Symbol Definitions Symbol Definition Table of Contents 205 Configuration Prompt Definitions147 Operation 243 219233 271 Figures DC330X-EE-XXX-X2, DC330X-AA-XXX-X2 Tables 154 246 Xii UDC 3300 Controller Product Manual Introduction Pharmaceuticals, and testing and environmental workConfigurable parameters 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 ToBEGIN KeySPn OTI UDC 3300 Controller Product Manual Overview Introduction What’s in this section?Topic See Normal Mode SpecificationsStray Rejection Common Mode Design Solid State Relays One or Two Current Output IsolatedElectromechanical Relays One or Two Open Collector Outputs One or Two RS422/485 Ascii RS422/485 Modbus Power Consumption Power Inrush Current WeightDmcs 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 Step Procedure for Mounting the Controller Action Refer to -3 and follow the procedure in -2 to mountMounting procedure Controller Electrical Noise Precautions WiringControl/alarm circuit wiring Electrical considerations Permissible Wiring Bundling Bundle No Wire Functions Shows which wire functions should be bundled togetherPermissible wire bundling Identify your wiring requirements Wiring Requirements Using the information contained in the model number, selectWiring the controller Controller accordingly Wiring Diagrams Line voltage wiring Controller 4 mm2Due to the voltage drop caused by the in-rush current Except 0-10 Volts Input #1/Input #2 connectionsThermocouple MV or Volts Volts Milliamps 5V Connections MA Connections Two Hlai replace second Llai connectionsHigh Level Analog Input Connections See Below 22 + 23 + Time proportional output L2/N PowerAlarm Relay #1 Load Electromechanical Relay Output-Model DC330X-EE-XXX Alarm Relay #1 Load AC Load Alarm Relay #2 LoadRelay Load Power AC Load 10 10-amp Solid State Relay Output-Model DC330X-SS-XX Time Proportional Simplex Controller Load L2/N Output or Alarm LoadCurrent output/ universal output connections Ohms 16 + Output Type CurrentRelay #1 Mechanically linked To motor Position proportional output connectionsCalibration Connect shield to ground At one end only 1000 Ω Auxiliary output connectionsAuxiliary Load Digital inputs connections TX-/RX Full duplex wiringMaster L2/N Do not mix half Master 120 OhmResistor Configure Diode here to reduce Zero VAL = Span VAL =+16 26 + 250 ohm Resistor Voltage at transmitter Control and Alarm Relay Contact Information Lists the Alarm Relay contact informationLists the Control Relay contact information Topic Continuous background tests that are being performedIntroduction 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 Step Operation Configuration ProcedureIntroduction Procedure Press SET UP Lower Display Step Operation Function prompts Loop 1 Tuning Parameters Set Up GroupFactory Setting 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 Setpoint rate SP Ramp, SP Rate, or SP Programming Set Up GroupLists all the function prompts in the SP Ramp Set Up group Function prompts Function Prompt SEG3RATE SEG4 SP SEG4TIME Recycles Soak DEV Prog END State Keyreset HotstartSEG1RATE SEG2 SP SEG2TIME SEG5RATE SEG6 SP SEG6TIME Accutune Set Up Group Accutune Group Function Prompts Lists the function prompts in the Accutune Set Up groupFactory Refer Setting Function Selections or Algorithm Data Set Up Group Introduction Function promptsAlgorithm Group Function Prompts Math K Calc HI Calc LO ALG1 INA ALG1 INB ALG1 INC INP ALG1None PCO SEL PCT CO ATM Pres ALG1BIAS INP ALG2 ALG2 INB Factory Setting ReferALG2 INA ALG2 INC Totalize Xxxxxxx TOT Scal TOT SEC Rset ? TOT Rate OUT ALG Output Algorithm Parameters Set Up GroupOutput Algorithm Group Function Prompts OUT2 ALG Rlystate IN1 Type XMITTER1 Input 1 Parameters Set Up GroupInput 1 Group Function Prompts Selections or Analytic IN1 HI IN1 LO Ratio BURNOUT1 Bias IN1Filter 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 Dropoff Deadband OUT Hyst Failmode Failsafe Swfail OUT RatePCT/M UP PCT/M DN 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 Group Function Prompts Options Set Up GroupPrompts will not appear AUX OUT CUR OUT2 +RUN DIG1 COM DIG2 COM+DISAT None Disabl Shedenab Shedtime Parity Baud Communications Set Up Group15 Communications Group Function Prompts 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 A1S1 EV A1S1TYPE A1S2TYPE A2S1TYPE A2S2TYPEA1S1 H L A1S2 H L A2S2 H L A2S1 H LA2S1 EV A2S2 EV AL Hyst ALM OUT1 Block Decimal Display Parameters Set Up GroupDisplay Group Function Prompts DECIMAL2 Calibration Group Calibration data Maintenance Group Function Prompts Maintenance Set Up GroupOthers, to keep track of maintenance needs Elapsed Time Timer Status test data Counter Number of Counts Password Reset TypeStatus Group 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 Upper Display Range of Setting Or Selection Introduction Set this group last Tuning group promptsTuning Group Prompt Definitions Lower Display 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 Disabl Tune TUN+PV SP+PV Demand Tuning Plus PV Adaptive TUNE- SameSetpoint Tuning Plus PV Adaptive TUNE- Same 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 Input High Select with Ratio and BIAS- This RelhumSummer with Ratio and BIAS- The following 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 FFWDM2 Lower Display Upper Display Prompt Range of SettingFWR2  Mult PCT H2 ALG2BIAS Where Summary of Flow Values At Values Conditions Flow Sfcm X1 Input Value X Axis 8SEG CH1X0 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 Input 1 group prompts Lower Display Prompt Upper Display Parameter Range of Setting DefinitionBias, filter, burnout, and emissivity Input 1 Group Definitions Conductivity Xmitter AnalyticORP Resistivity IN1 LO Ratio Bias IN1 Filter Burnout EMISSIV1 Input 2 Group Definitions SlidewireIntroduction Input 2 group prompts Lower Display Prompt IN2 Type IN3 Type Introduction Input 3 group prompts Lower Display PromptInput 3 Group Definitions XMITTER2 IN3 HI IN3 LO Ratio Bias IN3 Filter Input Introduction Control group prompts Lower Display PromptPV Source PID Sets Input Algorithm Three PID Sets SW Value LSP’S2PV SW 2SP SW Gain S Setpoint Select RSP SRC Autobias SP Track Manual LSP RSP Control Output DIRECTION- Select direct or reverse acting For Three Position Step Control OnlySP HiLIM OUT Rate PCT/M UP Dropoff Failsafe ModeOUTLoLIM Hi LIM Lo LIM OUT Hyst Failmode Failsafe Swfail PBorGAIN PB PCT GainRPM MIN PV 2 SRC Introduction Control 2 group prompts11 Control 2 Group Definitions Lower Display Prompt 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 Options Group Definitions Selection with desired scalingOption group prompts Lower Display Prompt 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 Any Digital Input Selection Plus RUN Setpoint DIG DIG 1 COMDIG DIG2 COM Digital Input 2 Selections ComSTATE Com Addr ComADDR2 Introduction Communications group prompts13 Communications Group Definitions Lower Display Prompt Shed Enab Shedtime Parity Baud Duplex WsfloatEven Parity To LSP To CSP Last Toauto FsafeShed SP 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 A1S1TYPE No Alarm InputAlarm on Manual Mode Loop 1 Note Event on SP Programming Event OFF SP Programming High LOW Begin END High Alarm LOW AlarmA1S2TYPE A2S1TYPE A2S2TYPE 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 Calibration Data Maintenance GroupMaintenance Group Definitions Input Calibration in this manual for complete information TIME1 Gsoak Sootng DIGIN1 DIGIN2 MAN2 Status Test Data Failure. Refer to the Troubleshooting in this manual forCOUNTS1 COUNTER2 COUNTS2 COUNTER3 COUNTS3 Password RES Type Complete information Operation How to Power Up the Controller Keys Procedure for Testing the Displays and Keys Press Key Pressed Lower Display Entering a Security Code Introduction Security code numbers ProcedureStep Procedure for Entering a Security Code Press Action 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 Enter the local Start-up ProcedureStart-up procedure is given in Table Setpoint Operating Modes Available modes Mode definitionsOperating Mode Definitions 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 Single Setpoint Ramp Configuring the setpoint ramp Procedure14 Procedure for Configuring a Setpoint Ramp Step Operation 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 Rate Rset Set switchover valueSet tuning constant values for each set RSET2 = 1 or Alarm Setpoints Introduction Procedure for displaying the alarm setpoints 21 Control Loop Selections Input Input Algorithm Two Loops of Control OverviewIntroduction Selections 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 25 Procedure for Selecting Output Algorithm Step Operation Configuring Two Loops of Control24 Procedure for Selecting 2-loop 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 28 Digital Display Indication-Two Loops IndicatorMonitoring Two Loops of Control Loop Indication Operating Two Loops of Control Loop operationOperating modes and setpoint source Keyboard operation Three Position Step Control algorithm Loop 1 only allows Power-up outputThree Position Step Control Algorithm 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 Stop MAN FS Timer AM STATo RUN TRACK1 TRACK2 Display Indication Means that the parameter is configured and the actionWill occur when the digital input is active Action on contact closure Digital Inputs 1 and 2 Combination Action Example Auto/Manual Station Introduction FunctionState DI #1 Open DI #1 Closed Up Group Function Prompts Refer to -33 and set up the controller in the order shownDescription Configuration Press To Enter Remarks Value or Selection Algorithm Step PressUp Group Function Prompts Press To Enter Remarks Options Introduction How it works Configuration Fuzzy Overshoot Suppression Accutune Rules How Tune demand tuning works34 is a list of rules for Accutune 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 Step Action Using SP tuning at start-up37 Procedure for Using SP Tuning at Start-up MANUAL/AUTO Using SP tuning at start-up for duplex heat/cool SP tuning after start-up Aborting SP tuning Error prompt accessing procedure Values are entered and used until retuning occurs againRetuning 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 HealthWatch maintenance alarms When the desired threshold is reachedSee .18 Maintenance for details on using the various 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 Alarms on the setpoint program Prompt hierarchy Make sure SP Ramp and SP Rate are disabled firstSetpoint Program Data Entry Procedure Press Result Entering the Setpoint Program Data Prompt Hierarchy and Available Selections Value or Selection use or SEG8 SP SEG8TIME SEG9RAMP SEG9RATE SG10 SP SG10TIME Definition Value or Selection use orSEG2 SP SEG2TIME SEG3RAMP SEG3RATE SG11RAMP SG11RATE SG12 SP SG12TIME Local Setpoint Value Run/Monitor the ProgramIntroduction Run/monitor functions 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 RTD Minimum and Maximum Range ValuesHoneywell Radiamatic Type RH Type RI 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 250Ω Resistor Assy Input 3-Wire terminals as shown belowTo 20 mA inputs Copper Leads To 20 mA Source Make sure you have Lockout set to NONE. See Section Input #1, #2, or #3 Calibration ProcedureInput #1, #2, or #3 Calibration Procedure From initial value to final 100 % value Step Description If… Then… Restoring Factory Calibration Step Operation How to restore it ProcedureRestoring Factory Calibration 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 Procedure for calibrating the Position Proportional outputLockout in Tuning Set Up group is set to NONE. See Section 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 Upper Display Power-up TestsWhat happens at power-up Test failures Introduction How to check the status tests Status TestsRAM Test Conf Test CAL Test Fact CRC Fail Status TestsRAM Test Conf CAL Test Fact CRC Pass EE Fail Background TestsIntroduction Background tests INP1FAIL INP2FAIL INP3FAIL PV = INP1 + INP1 Bias Lower Display Reason for Failure How to Correct the ProblemINP1 RNG INP2 RNG INP3 RNG PV Limit RV Limit RV = INP2 X Ratio + Bias Troubleshooting procedure indicated to correct the problem Controller Failure SymptomsCompare your symptoms with those shown in -7 and refer to Reacting Troubleshooting Power Failure Symptoms Step What to do Troubleshooting ProceduresEquipment needed Procedure #1 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 MCU Printed wiring board identificationOn Digital Input and MCU/Output boards Prom 20 Power Input Board Replacement Procedure Step Action 19 Second Input Board Replacement Procedure Step ActionPower input board 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 Key Part Number Parts identificationParts not shown 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 PB or Gain Two Sets of Tuning Parameters for Single Output OperationTuning function prompts for HEAT/COOL are 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