UDC 3300 Universal Digital Controller Product Manual 51-52-25-55D 4/00 Sensing and Control
Copyright, Notices, and Trademarks Printed in U.S.A. – © Copyright 2000 by Honeywell Revision D – April, 2000 WARRANTY/REMEDY Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of coverage, Honeywell will repair or replace without charge those items it finds defective.
About This Document Abstract This manual describes the installation, configuration, operation, and maintenance of the UDC3300 Controller.
Symbol Definitions The following table lists those symbols used in this document to denote certain conditions. Symbol Definition This CAUTION symbol on the equipment refers the user to the Product Manual for additional information. This symbol appears next to required information in the manual. WARNING PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms, 42.4 Vpeak, or 60 Vdc may be accessible.
Table of Contents SECTION 1 – OVERVIEW.................................................................................................. 1 1.1 1.2 Introduction...................................................................................................... 1 Operator Interface ........................................................................................... 3 SECTION 2 – INSTALLATION........................................................................................... 7 2.1 2.2 2.3 2.
SECTION 4 – CONFIGURATION PROMPT DEFINITIONS ............................................ 79 4.1 4.2 4.3 4.4 4.5 4.6 4.7 4.8 4.9 4.10 4.11 4.12 4.13 4.14 4.15 4.16 4.17 4.18 4.19 Overview ....................................................................................................... 79 Loop 1 Tuning Parameters Set Up Group..................................................... 80 Loop 2 Tuning Parameters Set Up Group.....................................................
SECTION 7 – INPUT CALIBRATION ............................................................................ 219 7.1 7.2 7.3 7.4 7.5 7.6 Overview...................................................................................................... 219 Minimum and Maximum Range Values....................................................... 220 Preliminary Information................................................................................ 221 Input #1, #2, or #3 Set Up Wiring ...........................
Figures Figure 1-1 Figure 2-1 Figure 2-2 Figure 2-3 Figure 2-4 Figure 2-5 Figure 2-6 Figure 2-7 Figure 2-8 Figure 2-9 Figure 2-10 Figure 2-11 Figure 2-12 Figure 2-13 Figure 2-14 Figure 2-15 Figure 2-16 Figure 2-17 Figure 2-18 Figure 2-19 Figure 2-20 Figure 3-1 Figure 4-1 Figure 4-2 Figure 5-1 Figure 5-2 Figure 5-3 Figure 5-4 Figure 5-5 Figure 5-6 Figure 6-1 Figure 6-2 Figure 7-1 Figure 7-2 Figure 7-3 Figure 7-4 Figure 7-5 Figure 7-6 Figure 7-7 Figure 8-1 Figure 8-2 Figure 9-1 Figure 9-2 Figure 9-3 Figure 9-
Tables Table 1-1 Table 2-1 Table 2-2 Table 2-3 Table 2-4 Table 2-5 Table 2-6 Table 2-7 Table 2-8 Table 3-1 Table 3-2 Table 3-3 Table 3-4 Table 3-5 Table 3-6 Table 3-7 Table 3-8 Table 3-9 Table 3-10 Table 3-11 Table 3-12 Table 3-13 Table 3-14 Table 3-15 Table 3-16 Table 3-17 Table 3-18 Table 4-1 Table 4-2 Table 4-3 Table 4-4 Table 4-5 Table 4-6 Table 4-7 Table 4-8 Table 4-9 Table 4-10 Table 4-11 Table 4-12 Table 4-13 Table 4-14 Table 4-15 Table 4-16 Table 5-1 Table 5-2 Table 5-3 Figure 5-1 Table 5-4 4/00
Table 5-5 Table 5-6 Table 5-7 Table 5-8 Table 5-9 Table 5-10 Table 5-11 Table 5-12 Table 5-13 Table 5-14 Table 5-15 Table 5-16 Table 5-17 Table 5-18 Table 5-19 Table 5-20 Table 5-21 Table 5-22 Table 5-23 Table 5-24 Table 5-25 Table 5-26 Table 5-27 Table 5-28 Table 5-29 Table 5-30 Table 5-31 Table 5-32 Table 5-33 Table 5-34 Table 5-35 Table 5-36 Table 5-37 Table 5-38 Table 5-39 Table 6-1 Table 6-2 Table 6-3 Table 6-4 Table 7-1 Table 7-2 Table 7-3 Table 7-4 Table 7-5 Table 7-6 Table 8-1 Table 8-2 Table 8-3 Ta
Table 9-2 Table 9-3 Table 9-4 Table 9-5 Table 9-6 Table 9-7 Table 9-8 Table 9-9 Table 9-10 Table 9-11 Table 9-12 Table 9-13 Table 9-14 Table 9-15 Table 9-16 Table 9-17 Table 9-18 Table 9-19 Table 9-20 Table 9-21 Table 9-22 Table 9-23 Table 10-1 Table 10-2 Table 11-1 Table 11-2 4/00 Procedure for Identifying the Software Version............................................................246 Power-up Tests ......................................................................................................
xii UDC 3300 Controller Product Manual 4/00
Section 1 – Overview 1.1 Introduction Function The UDC 3300 is a microprocessor-based stand alone controller. It combines the highest degree of functionality and operating simplicity offered in a 1/4 DIN size controller. With a typical accuracy of ± 0.20 % of span, the UDC 3300 is an ideal controller for regulating temperature and other process variables in numerous heating and cooling applications, in metal working, food, and pharmaceuticals, and testing and environmental work.
EMC Classification: Group 1, Class A, ISM Equipment (EN55011, emissions), Industrial Equipment (EN50082-2, immunity) Method of EMC Assessment: Technical File (TF) Declaration of Conformity: 51309602-000 Deviation from the installation conditions specified in this manual, and the special conditions for CE conformity in Section 2.1, may invalidate this product’s conformity with the Low Voltage and EMC Directives.
1.2 Operator Interface Displays and indicators Figure 1-1 shows the operator interface and defines the displays and indicators. The function of the keys is shown in Table 1-1.
Function of keys Table 1-1 shows each key on the operator interface and defines its function. Table 1-1 Function of Keys Key Function SET UP • Places the controller in the Configuration Set Up group select mode. Sequentially displays Set Up groups and allows the FUNCTION key to display individual functions in each Set Up group. FUNCTION LOOP 1/2 • Used in conjunction with the SET UP key to select the individual functions of a selected Configuration Set Up group.
Key LOWER DISPLAY Function 1PV 2PV AUX OC1 OC2 SPn • (Sigma) BIA TUNE OFF TUNE RUN ToBEGIN OTI = = = = = = = = = = For Cascade or 2 Loops For Cascade or 2 Loops Auxiliary Output Characterized Output 1 Characterized Output 2 Setpoint Now (for setpoint rate) Current Totalizer Value Output Bias/Manual Reset Value Appears when Limit Cycle tuning is disabled Press ▲ and LOWER DISPLAY to initiate Limit Cycle tuning. Display will read TUNE RUN.
6 UDC 3300 Controller Product Manual 4/00
Section 2 – Installation 2.1 Overview Introduction Installation of the UDC 3300 Controller consists of mounting and wiring the controller according to the instructions given in this section. Read the pre-installation information, check the model number interpretation and become familiar with your model selections, then proceed with installation. What’s in this section? This section contains the following information: Topic 4/00 See Page 2.1 Overview Specifications 7 8 2.
Pre-installation information If the controller has not been removed from its shipping carton, inspect the carton for damage and remove the controller. Inspect the unit for any obvious shipping damage and report any damage due to transit to the carrier. Make sure that the carton with the controller includes • a bag containing mounting hardware and • a bag containing input resistors. Check that the model number shown on the inside of the case agrees with what you have ordered.
Design (continued) Isolation (Functional) AC Power: Is electrically isolated from all other inputs and outputs to withstand a HIPOT potential of 1900 Vdc for 2 seconds per Annex K of EN61010-1. Analog Inputs and Outputs: Are isolated from each other and all other circuits at 850 Vdc for 2 seconds. Digital Input and Digital Output: Are isolated from all other circuits at 850 Vdc for 2 seconds.
Design (continued) Digital Inputs (Optional) (Isolated) +15 Vdc source for external dry contacts or isolated solid state contacts. The Digital Input option detects the state of external contacts for either of the two inputs. On contact closure the controller will respond according to how each digital input is configured. Opening contact causes return to previous state.
Environmental and Operating Conditions Parameter Reference Rated Operative Limits Transportation and Storage Ambient Temperature 25 ± 3 °C 77 ± 5 °F 15 to 55 °C 58 to 131 °F 0 to 55 °C 32 to 131 °F –40 to 66 °C –40 to 151 °F Relative Humidity 10 to 55* 10 to 90* 5 to 90* 5 to 95* Vibration Frequency (Hz) Acceleration (g) 0 0 0 to 70 0.4 0 to 200 0.6 0 to 200 0.
2.2 Model Number Interpretation Model number The model number interpretationis shown in Figure 2-1. Write the model number into the spaces provided and compare it to the model number interpretation. This information will also be useful when you wire your controller.
2.3 Mounting Physical considerations The controller can be mounted on either a vertical or tilted panel using the mounting kit supplied. Adequate access space must be available at the back of the panel for installation and servicing activities. The overall dimensions and panel cutout requirements for mounting the controller are shown in Figure 2-2. Overall dimensions Figure 2-2 shows the overall dimensions for mounting the controller. Figure 2-2 Dimensions 92 3.622 96 3.780 +0.008 -0.0 +0.03 -0.
Mounting method Before mounting the controller, refer to the nameplate on the inside of the case and make a note of the model number. It will help later when selecting the proper wiring configuration. Figure 2-3 shows you the mounting method for the UDC 3300 controller. Figure 2-3 Mounting Method Panel 22605 Mounting procedure Refer to Figure 2-3 and follow the procedure in Table 2-2 to mount the controller.
2.4 Wiring Electrical considerations The controller is considered “rack and panel mounted equipment” per EN 61010-1, Safety Requirements for Electrical Equipment for Measurement, Control, and Laboratory Use, Part 1: General Requirements. Conformity with 72/23/EEC, the Low Voltage Directive requires the user to provide adequate protection against a shock hazard. The user shall install this controller in an enclosure that limits OPERATOR access to the rear terminals.
Permissible wire bundling Table 2-3 shows which wire functions should be bundled together. NOTE For installation where high EMI/RFI noise cannot be avoided, we recommend you use shielded twisted pair wires for the signals in bundle 2. Table 2-3 Permissible Wiring Bundling Bundle No. 1 Wire Functions • Line power wiring • Earth ground wiring • Control relay output wiring • Line voltage alarm wiring 2 Analog signal wire, such as: • Input signal wire (thermocouple, 4 to 20 mA, etc.
Wiring the controller Using the information contained in the model number, select the appropriate wiring diagrams from the figures listed below and wire the controller accordingly.
2.5 Wiring Diagrams Composite wiring diagram Figure 2-4 is a composite wiring diagram of the UDC 3300 controller. It identifies the terminal designations and their functions. Refer to the individual diagrams listed to wire the controller according to your requirements.
Line voltage wiring This equipment is suitable for connection to 90-264 Vac or 24 Vac/dc, 50/60 Hz, power supply mains. It is the user’s responsibility to provide a switch and non-time delay (North America), quick-acting, high breaking capacity, Type F, (Europe) 1/2 A, 250 V fuse(s) or circuit-breaker for 90264 V; or 1 A, 125 V fuse or circuit breaker for 24 Vac/dc operation, as part of the installation.
Input #1/Input #2 connections Figure 2-6 shows the wiring connections for Input #1 and Input #2. Figure 2-6 INPUT #2 Refer to Table 2-4 for Input 2 Jumper selections. 3 Thermocouple Use Thermocouple extension wire only 1 22 R 22 R 23 + 23 + 24 – 24 – Carbon, mV mV or Volt or Volt source source 22 R + 23 + – 24 – 1 The 250Ω load resistor for 4-20 mA or the voltage divider for 0-10 volts or the 500 ohm C/J compensation resistor is supplied with the controller when the input is specified.
Two HLAI replace second LLAI connections Figure 2-7 shows the wiring connections for replacing the second LLAI with two HLAI. Figure 2-7 Two HLAI Replace 2nd LLAI Connections ATTENTION: Remove Input 2 jumper when ATTENTION: replacing withwhen two Removesecond Input 2LLAI jumper HLAI. Refersecond to TableLLAI 2-4.with two replacing HLAI. Refer to Table 2-3.
Time proportional output There are three types of Time Proportional outputs available on the UDC 3300. • Electromechanical Relay Output (Model DC330X-EE-XXX)–Figure 2-8 • Solid State Relay Output (Model DC330X-AA(SS)-XXX)–Figure 2-9 • Open Collector Output (Model DC330X-TT-XXX)–Figure 2-11 The Alarm wiring connections are the same for all three outputs. For Control and Alarm Relay Contact information, see Tables 2-7 and 2-8.
Time proportional output, continued Figure 2-9 shows the Output and Alarm wiring connections for models with Solid State Relay Output (Model DC330X-AA-XX). For Control and Alarm Relay Contact information, see Tables 2-7 and 2-8. Figure 2-9 Solid State Relay Output—Model DC330X-AA-XX Time Proportional Simplex 1 L1 L2/N Output Relay#1 22 23 Alarm Relay#2 2 N.O. 4 Dummy Resistor 1 5 Alarm Relay #2 Load N.C. 6 25 7 Alarm Relay#1 AC Load Supply Power N.O.
Time proportional output, continued Figure 2-10 shows the wiring connections for the external 10-amp Solid State Relay Output (Model DC330X-SS-XX). Figure 2-10 10-amp Solid State Relay Output—Model DC330X-SS-XX L2/N L1 LOAD HOT 1 AC 10 1 L1 11 +2 L2 12 –3 22 13 4 23 14 +5 24 15 –6 25 16 7 26 17 8 Solid State Relay Black 27 Output 1 White – + Output 2 24165 9 Green 1 24 External solid state relays are rated at 15 amps @25°C derated to 10 amps at 55°C.
Time proportional output, continued Figure 2-11 shows the Output and Alarm wiring connections for models with Open Collector Output (DC330X-TT-XXX) For Control and Alarm Relay Contact information, see Tables 2-7 and 2-8. Figure 2-11 Open Collector Output—Model DC330X-TT-XXX Time Proportional Simplex Customer Supplied Solid State Relay 3 Customer Supplied Electromechanical Relay 1 + Output #1 1 – 1 + 2 3 + Output #1 1 – – 4 6 7 Alarm Relay #2 Load To terminal 4 or 6 N.C . 8 N.O.
Current output/ universal output connections Figure 2-12 shows the Output and Alarm wiring connections for models with Current Output (Model DC330X-KE-XXX and Model DC330X-C0-XXX). See Table 2-5 for wiring restrictions. For Control and Alarm Relay Contact information, see Tables 2-7 and 2-8.
Current output/ universal output connections, continued Figure 2-13 shows the Output and Alarm wiring connections for models with a Current Output (Auxiliary Output) and three Relay Outputs (Model DC330X-EE-2XX). See Table 2-6 for wiring restrictions. For Control and Alarm Relay Contact information, see Tables 2-7 and 2-8. Figure 2-13 – Auxiliary + Auxiliary Output and Three Relay Outputs 1 Output Relay#1 Load 0-1000 N.C.
Position proportional output connections Figure 2-14 shows the Output and Alarm wiring connections for models with Position Proportional Output or Three Position Step Control (Models DC330X-EE-XXX-X2, DC330X-AA-XXX-X2). For Control and Alarm Relay Contact information, see Tables 2-7 and 2-8.
Auxiliary output connections Figure 2-15 shows the wiring connections for the Auxiliary Output option (Models DC330X-XX-2XX, DC330X-XX-5XX). Figure 2-15 Auxiliary Output Connections—Models DC330X-XX-2XX, DC330X-XX-5XX For Duplex Current Output use Control Output for Output 1 (heat) Attention: Both current outputs (control and auxiliary) are isolated from each other, case ground, and all inputs.
Communications option There connections are two types of Communications option available: • RS422/485/Modbus (Model DC330X-XX-1XX or DC330X-XX-5XX)—Figure 2-17 [also refer to Document #51-51-25-35 (RS422/485 ASCII) or #51-52-25-66 and #51-52-25-70 (Modbus)] • DMCS (Model DC330X-XX-4XX)—Figure 2-18 (also refer to Document #82-50-10-23) Figure 2-17 RS422/485/Modbus Communications Option Connections MODBUS OR RS422/485 HALF DUPLEX L1 Master L2/N 12 22 13 23 14 24 15 25 16 26 17 SHD SHD 1 T
Figure 2-18 shows the wiring connections for the DMCS Communications option (Model DC330X-XX-4XX). Figure 2-18 DMCS Communications Option Connections DMCS Communications Master L1 L2/N 12 22 SHD 13 23 14 24 15 25 16 26 17 1 SHD + D– D D 120 Ohm Resistor Do not run these lines in the same conduit as AC power Use shielded twisted pair cables (Belden 9271 Twinax or equivalent) *DMCS: Maximum 31 drops. 4/00 + D– 27 1 DMCS is a proprietary protocol.
Transmitter power for 4-20 mA 2-wire transmitter—open collector alarm 2 output The wiring diagram example shown in Figure 2-19 (Model DC330X-XT-XXX) provides 30 Vdc at terminals 5 and 6 with the capability of driving up to 22 mA, as required by the transmitter which is wired in series. If the transmitter terminal voltage must be limited to less than 30 volts, you can insert a zener diode between the positive transmitter terminal and terminal 5.
Transmitter power for 4-20 mA 2-wire transmitter—auxiliary output The wiring diagram example shown in Figure 2-20 (Model DC330X-XX-2XX or DC330X-XX-5XX) provides 30 Vdc at terminal 16 with the capability of driving up to 22 mA, as required by the transmitter which is wired in series. If the transmitter terminal voltage must be limited to less than 30 volts, you can insert a zener diode between the positive transmitter terminal and terminal 16.
2.6 Control and Alarm Relay Contact Information Control relays Table 2-7 lists the Control Relay contact information. ATTENTION Control relays operate in the standard control mode; i.e., energized when output state is on. Table 2-7 Unit Power Control Relay Contact Information Control Relay Wiring Off On Alarm relays Control Relay Contact #1 or #2 Output Indicator Status N.O. Open N.C. Closed N.O. Open Closed Off On N.C.
Section 3 – Configuration 3.1 Overview Introduction Configuration is a dedicated operation where you use straightforward keystroke sequences to select and establish (configure) pertinent control data best suited for your application. What’s in this section? The table below lists the topics that are covered in this section. Topic Prompts 4/00 Page 3.1 Overview 35 3.2 Configuration Prompts 36 3.3 How to Get Started 38 3.4 Configuration Tips 39 3.5 Configuration Procedure 40 3.
3.2 Configuration Prompts Diagram: prompt hierarchy Figure 3-1 shows an overview of the UDC 3300 Set Up prompts and their associated Function prompts. Read from left to right.
Set Up Group INPUT 1 Function Prompts IN1 TYPE XMITTER1 ANALYTIC IN1 HI IN1 LO RATIO 1 BIAS IN1 FILTER 1 BURNOUT1 EMISSIV1 IN2 TYPE XMITTER2 ANALYTIC IN2 HI IN2 LO RATIO 2 BIAS IN2 FILTER 2 BURNOUT2 EMISSIV2 INPUT 3 IN3 TYPE XMITTER3 IN3 HI IN3 LO RATIO 3 BIAS IN3 FILTER 3 CONTROL PV SOURC PID SETS SW VALUE LSP’S RSP SRC AUTOBIAS SP TRACK PWR MODE PWR OUT SP HiLIM SP LoLIM ACTION OUT RATE PCT/M UP PCT/M DN OUTHiLIM OUTLoLIM I Hi LIM I Lo LIM DROPOFF DEADBAN
3.3 How To Get Started Read the configuration tips Read “Configuration Tips” shown on the next page. These tips will help you to easily and quickly accomplish the tasks at which you will be working when you configure your controller. Read configuration procedure Read “Configuration Procedure”. This procedure tells you how to access the Set Up groups, and the Function parameters within each of these groups that are shown in the Prompt Hierarchy in Figure 3-1.
3.4 Configuration Tips Introduction Listed below in Table 3-1 are some tips that will help you enter the configuration data more quickly. Table 3-1 Configuration Tips Function Tip Displaying Groups Use the SET UP key to display the Set Up groups. The group titles are listed in this section in the order that they appear in the controller. Displaying Functions Scrolling Use the FUNCTION key to display the individual parameters under each group.
3.5 Configuration Procedure Introduction Each of the Set Up groups and their functions are pre-configured at the factory. The factory settings are shown in Tables 3-3 through 3-18 which follow this procedure. If you want to change any of these selections or values, follow the procedure in Table 3-2. This procedure tells you the keys to press to get to any Set Up group and any associated Function parameter prompt.
Step 4 Operation Press Select other Function Parameters FUNCTION LOOP 1/2 Result Successive presses of the FUNCTION key will sequentially display the other function prompts of the Set Up group you have selected. Stop at the function prompt that you want to change, then proceed to the next step. 5 Change the value or selection These keys will increment or decrement the value or selection that appears for the function prompt you have selected.
3.6 Loop 1 Tuning Parameters Set Up Group Function prompts Table 3-3 lists all the function prompts in the Tuning Set Up group. How the Algorithm and Control Set Up groups are configured determines which prompts will appear. Table 3-3 Function Prompt Lower Display Tuning Group Function Prompts Function Name Selections or Range of Setting Factory Setting Refer to 0.1 to 9999 % -- Section 4.2 0.001 to 1000 1.
Function Prompt Lower Display Function Name Selections or Range of Setting Factory Setting Refer to ENABLE Section 4.2 Upper Display RUN HOLD** Run/Hold Key Lockout DISABL ENABLE PVEUVAL1 PVEUVAL2 PVEUVAL3 PVEUVAL4 PVEUVAL5 PVEUVAL6 PVEUVAL7 PVEUVAL8 PV1 (through PV8) Value for Gain Scheduling PV value within the PV limits. In engineering units GAINVAL1* GAINVAL2* GAINVAL3* GAINVAL4* GAINVAL5* GAINVAL6* GAINVAL7* GAINVAL8* Gain 1 (through Gain 8) Value for Gain Scheduling 0.
3.7 Loop 2 Tuning Parameters Set Up Group (Cascade or Two Loops Function prompts Table 3-4 lists all the function prompts in the Tuning 2 Set Up group. This group is only displayed if the controller is configured for Cascade or 2-Loop control (prompt PIDLOOPS in Algorithm Data Set Up group). Table 3-4 Function Prompt Lower Display Tuning Loop 2 Group Function Function Name Selections or Range of Setting Factory Setting Refer to -- Section 4.
3.8 SP Ramp, SP Rate, or SP Programming Set Up Group Single Setpoint Ramp The Setpoint Ramp Set Up group contains the Function parameters that let you configure a single setpoint ramp to occur between the current local setpoint and a final setpoint over a time interval (SP RAMP). Setpoint rate The Setpoint Ramp Set Up group also contains the function parameters that let you configure a specific rate of change for any Local Setpoint change (SP RATE). It includes selections for Rate Up and Rate Down.
Function Prompt Function Name Lower Display Selections or Range of Setting Factory Setting Refer to Section 4.4 Upper Display RECYCLES Number of Program Recycles 0 to 99 recycles –– SOAK DEV Guaranteed Soak Deviation Value 0 to 99 The number selected will be the PV value (in engineering units) above or below the setpoint outside of which the timer halts.
3.9 Accutune Set Up Group Introduction The Accutune Set Up group offers these selections: • FUZZY Fuzzy Overshoot Suppression—Uses fuzzy logic to suppress or eliminate any overshoot that may occur when the PV approaches setpoint. • TUNE Demand Tuning—The tuning process is initiated through the operator interface keys or via a digital input (if configured). The algorithm then calculates new tuning parameters and enters them in the tuning group. TUNE does operate with 3 Position Step Control.
Function prompts Table 3-6 lists the function prompts in the Accutune Set Up group. Table 3-6 Function Prompt Accutune Group Function Prompts Function Name Lower Display Selections or Range of Setting Factory Setting Refer to Section 4.
3.10 Algorithm Data Set Up Group Introduction This data deals with various algorithms residing in the controller: • Control algorithms, • Input Math algorithms, • selecting the 1 or 2 PID Loops, • Output Override, • 2 Eight Segment Characterizers, • the Timer function, and • Totalizer function. • Gain Scheduler ATTENTION Math option (two algorithms, two characterizers, totalizer) and Two Loops of Control are only available on Expanded Model DC330E.
Function Prompt Lower Display Function Name Selections or Range of Setting Factory Setting Refer to NONE Section 4.6 Upper Display INP ALG1 Input 1 Algorithm (formulas are located in Section 4) ATTENTION All Input Algorithms operate in engineering units except feedforward which operates in percent of output units. PV or RSP source in the Control Set Up group must be set to IN AL1. MuDIV MULT CARB A CARB B CARB C CARB D FCC DEW PT OXYGEN MATH K Weighted Average Ratio or K 0.
Function Prompt Lower Display Function Name Selections or Range of Setting Factory Setting Refer to Upper Display CALC HI Calculated Variable High Scaling Factor for Input Algorithm 2 –999. To 9999. Floating (in engineering units) -- CALC LO Calculated Variable Low Scaling Factor for Input Algorithm 2 –999. To 9999.
Function Prompt Function Name Lower Display Selections or Range of Setting Factory Setting Refer to Upper Display X0 VALU2 X1 VALU2 X2 VALU2 X3 VALU2 X4 VALU2 X5 VALU2 X6 VALU2 X7 VALU2 X8 VALU2 Xn Input Value (X Axis) Y0 VALU2 Y1 VALU2 Y2 VALU2 Y3 VALU2 Y4 VALU2 Y5 VALU2 Y6 VALU2 Y7 VALU2 Y8 VALU2 Yn Output Value (Y Axis) TOTALIZE* Totalization Function DISABL INPUT1 IN AL1 IN AL2 ΣXXXXXXX Current Scale Factor (upper display) Actual Current Totalized Value (lower display) Σ*En Totalizer Sc
3.11 Output Algorithm Parameters Set Up Group Introduction This data deals with various Output types that are available for use in the controller. It also lists the Digital Output Status, the Current Duplex functionality, and Relay Time Cycle increments. Function prompts Table 3-8 lists all the function prompts in the Output Algorithm Set Up group.
3.12 Input 1 Parameters Set Up Group Introduction This data deals with various parameters required to configure Input 1. Function prompts Table 3-9 lists all the function prompts in the Input 1 Set Up group. Table 3-9 Function Prompt Lower Display Input 1 Group Function Prompts Function Name Selections or Range of Setting Factory Setting Refer to Section 4.
Function Prompt Function Name Lower Display Selections or Range of Setting Factory Setting Refer to Upper Display BIAS IN1 Input 1 Bias –999. to 9999. (in engineering units) 0 FILTER 1 Input 1 Filter 0 to 120 seconds 0 Burnout Protection NONE UP DOWN NO_FS Emissivity 0.01 to 1.00 BURNOUT1 EMISSIV1 NONE 0.
3.13 Input 2 Parameters Set Up Group Introduction This data deals with various parameters required to configure Input 2. Function prompts Table 3-10 lists all the function prompts in the Input 2 Set Up group. Table 3-10 Function Prompt Lower Display Input 2 Group Function Prompts Function Name Selections or Range of Setting Factory Setting Refer to 0-10mV Section 4.
3.14 Input 3 Parameters Set Up Group Introduction This data deals with various parameters required to configure Input 3. Function prompts Table 3-11 lists all the function prompts in the Input 3 Set Up group. Table 3-11 Function Prompt Input 3 Group Function Function Name Lower Display Selections or Range of Setting Factory Setting Refer to DISABL Section 4.
3.15 Loop 1 Control Parameters Set Up Group Introduction The functions listed in this group define how the Single Loop process controller or Loop 1 of a Two Loop process controller will control the process. Function prompts Table 3-12 lists all the function prompts in the Control Set Up group. Table 3-12 Function Prompt Lower Display Control Group Function Prompts Function Name Selections or Range of Setting Factory Setting Refer to INP 1 Section 4.
Function Prompt Lower Display Function Name Selections or Range of Setting Factory Setting Refer to DISABL Section 4.11 Upper Display OUT RATE Output Change Rate ENABLE DISABL PCT/M UP Output Rate Up Value 0 to 9999 % per minute 0 PCT/M DN Output Rate Down Value 0 to 9999 % per minute 0 OUTHiLIM High Output Limit –5.0 to 105 % of output 100 OUTLoLIM Low Output Limit –5.0 to 105 % of output 0.0 I Hi LIM High Reset Limit Within the range of the output limits 100.
3.16 Loop 2 Control Parameters Set Up Group Introduction The functions listed in this group define how Loop 2 of a Two Loop process controller will control the process. Only available on Expanded Controller Model DC330E-XX-XXX. Function prompts Table 3-13 lists all the function prompts in the Control 2 Set Up group. Table 3-13 Function Prompt Lower Display Control 2 Group Function Prompts Function Name Selections or Range of Setting Factory Setting Refer to Section 4.
Function Prompt Lower Display Function Name Selections or Range of Setting Factory Setting Refer to DISABL Section 4.12 Upper Display OUT RATE Output Change Rate ENABLE DISABL PCT/M UP Output Rate Up Value 0 to 9999 % per minute 0 PCT/M DN Output Rate Down Value 0 to 9999 % per minute 0 OUTHiLIM High Output Limit –5 to 105 % of output 100 OUTLoLIM Low Output Limit –5 to 105 % of output 0 I HiLIM High Reset Limit Within the range of the output limits 100.
3.17 Options Set Up Group Introduction This data deals with various options that are available with your controller. If your controller does not have any of these options the prompts will not appear. Function prompts Table 3-14 lists all the function prompts in the Options Set Up group. Table 3-14 Function Prompt Lower Display Options Group Function Prompts Function Name Selections or Range of Setting Factory Setting Refer to DISABL Section 4.
Function Prompt Function Name Lower Display Selections or Range of Setting Factory Setting Refer to DISABL Section 4.
3.18 Communications Set Up Group Introduction This data deals with the Communications option that is available with your controller. This option allows the controller to be connected to a host computer via an RS422/485 or Modbus protocol. If your controller does not have this option the prompts will not appear. Function prompts Table 3-15 lists all the function prompts in the Communications Set Up group.
Function Prompt Function Name Lower Display Selections or Range of Setting Factory Setting Refer to Upper Display WS_FLOAT Word swap order FP_B Floating point big endian FP_BB Floating point big endian with byte-swapped FP_L Floating point little endian FP_LB Floating point little endian with byte-swapped TX DELAY Transmission Delay 1 to 500 milliseconds Shed Controller Mode and Output Level LAST ToAUTO FSAFE TO MAN LAST SHEDSP Shed Setpoint Recall TO LSP TO CSP TO LSP UNITS Communicati
3.19 Alarms Set Up Group Introduction This data deals with the Alarms function that is available with your controller. There are two alarms available. Each alarm has two setpoints. You can configure each of these two setpoints to alarm on one of several events and you can configure each setpoint to alarm high or low. You can also configure the two setpoints to alarm on the same event and to alarm both high and low, if desired.
Function Prompt Lower Display Function Name Selections or Range of Setting Factory Setting Refer to NONE Section 4.
Function Prompt Lower Display Function Name Selections or Range of Setting Factory Setting Refer to HIGH Section 4.15 Upper Display A2S1 H L Alarm 2, Setpoint 1 State LOW HIGH A2S1 EV SP Programming Event Alarm State for Alarm 2, Setpoint 1 BEGIN END A2S2 H L Alarm 2, Setpoint 2 State LOW HIGH A2S2 EV SP Programming Event Alarm State for Alarm 2, Setpoint 2 BEGIN END -- AL HYST Alarm Hysteresis 0.0 to 100.0 % of output or span, as appropriate 0.
3.20 Display Parameters Set Up Group Introduction This data deals with the Decimal Place, Units of Temperature, Power Frequency, and Process ID Tag. Function prompts Table 3-17 lists all the function prompts in the Display Set Up group. Table 3-17 Function Prompt Lower Display Display Group Function Prompts Function Name Selections or Range of Setting Factory Setting Refer to Section 4.16 Upper Display DECIMAL Control Loop 1 Decimal Place XXXX XXX.X XX.XX X.
3.21 Calibration Group Calibration data 70 The prompts used here are for field calibration purposes. Refer to Section 7 – Calibration in this manual for complete information and instructions.
3.22 Maintenance Set Up Group Introduction The Maintenance group prompts are part of the HealthWatch feature (available only on DC330E model). These prompts let you count and time the activity of discrete events such as relays, alarms, control modes and others, to keep track of maintenance needs. Function prompts Table 3-18 lists all the function prompts in the Maintenance Set Up group.
Function Prompt Lower Display Function Name Selections or Range of Setting Factory Setting Refer to DISABL Section 4.
3.24 Configuration Record Sheet Basic Model: DC330B-XX-XXX DMCS Model: DC330D-XX-XXX Keep a record Group Prompt TUNING SP RAMP ACCUTUNE 4/00 Enter the value or selection for each prompt on this sheet so you will have a record of how your controller was configured.
Group Prompt CONTROL OPTIONS 74 Function Prompt Value or Selection Factory Setting PV SOURC PID SETS SW VALUE LSP’S RSP SRC AUTOBIAS SP TRACK PWR MODE PWR OUT SP HiLIM SP LoLIM ACTION OUT RATE PCT/M UP PCT/M DN OUTHiLIM OUTLoLIM I Hi LIM I Lo LIM DROPOFF DEADBAND OUT HYST FAILMODE FAILSAFE MAN OUT AUTO OUT PBorGAIN MINorRPM __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ ___
3.25 Configuration Record Sheet Expanded Model: DC330E-XX-XXX Keep a record Group Prompt TUNING 4/00 Enter the value or selection for each prompt on this sheet so you will have a record of how your controller was configured.
Group Prompt Function Prompt ACCUTUNE FUZZY ACCUTUNE ACCUTUN2 SP CHANG KPG SP CHAN2 KPG 2 CRITERIA CRITERA2 AT ERROR or AT ERR2 __________ __________ __________ __________ __________ __________ __________ __________ __________ Read Only CONT ALG PIDLOOPS CONT2ALG OUT OVRD TIMER PERIOD START L DISP INP ALG1 MATH K CALC HI CALC LO ALG1 INA ALG1 INB ALG1 INC PCO SEL PCT CO ATM PRES INP ALG2 MATH K2 CALC HI CALC LO ALG2 INA ALG2 INB ALG2 INC PCT H2 8SEG CH1 X0 VALUE X1 VALUE X2 VALUE X3 VALUE X4 VALUE X5 V
Group Prompt CONTROL CONTROL2 OPTIONS 4/00 Function Prompt Value or Selection Factory Setting PV SOURC PID SETS SW VALUE LSP’S RSP SRC AUTOBIAS SP TRACK PWR MODE PWR OUT SP HiLIM SP LoLIM ACTION OUT RATE PCT/M UP PCT/M DN OUTHiLIM OUTLoLIM I Hi LIM I Lo LIM DROPOFF DEADBAND OUT HYST FAILMODE FAILSAFE MAN OUT AUTO OUT PBorGAIN MINorRPM __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __
78 UDC 3300 Process Controller Product Manual 4/00
Section 4 – Configuration Prompt Definitions 4.1 Overview Introduction This section provides information for all the user configurable parameters listed in Section 3 - Configuration. If you are not familiar with these parameters, this section gives you the parameter prompt, the selection or range of setting that you can make, and a definition of how each parameter setting affects controller performance. It will also refer you to any other prompts that might be affected by your selection.
4.2 Loop 1 Tuning Parameters Set Up Group Introduction Tuning consists of establishing the appropriate values for the tuning constants for a single loop controller. These parameters are also for Loop 1 of a 2-Loop or Cascade control configuration. The Accutune feature automatically selects Gain, Rate, and Reset. This section also contains Keyboard Lockout/Security selections.
Lower Display Prompt RSET MIN or RSET RPM Upper Display Range of Setting or Selection 0.02 to 50.00 Parameter Definition RSET MIN = Reset in Minutes per Repeat RSET RPM = Reset in Repeats per Minute RESET (Integral Time) adjusts the controller’s output in accordance with both the size of the deviation (SP–PV) and the time it lasts. The amount of the corrective action depends on the value of Gain.
Lower Display Prompt SECURITY Upper Display Range of Setting or Selection 0 to 4095 Parameter Definition SECURITY CODE—The level of keyboard lockout may be changed in the Set Up mode. Knowledge of a security code may be required to change from one level to another. Select this number here, copy it, and keep it in a secure location. NOTE: The Security Code is for keyboard entry only and is not available via communications. Can only be changed if LOCKOUT selection is NONE.
Lower Display Prompt Upper Display Range of Setting or Selection PVEUVAL1 PV1 Value for Gain Scheduling PVEUVAL2 PV2 Value for Gain Scheduling PVEUVAL3 PV3 Value for Gain Scheduling PVEUVAL4 PV4 Value for Gain Scheduling PVEUVAL5 PV5 Value for Gain Scheduling PVEUVAL6 PV6 Value for Gain Scheduling PVEUVAL7 PV7 Value for Gain Scheduling PVEUVAL8 PV8 Value for Gain Scheduling Parameter Definition Gain Scheduling allows you to schedule eight user-defined Gain Values (GAINVALn) applied over ei
4.3 Loop 2 Tuning Parameters Set Up Group Introduction Tuning 2 (Loop 2) consists of establishing the appropriate values for the tuning constants for Loop 2 on 2-Loop or Internal Cascade control. Loop 2 is only available on Expanded Model DC330E. Tuning 2 group prompts Table 4-2 lists all the function prompts in the Tuning 2 Set Up group and their definitions.
4.4 Setpoint Ramp/Rate/Programming Set Up Group Introduction This data deals with enabling Single Setpoint Ramp function or Setpoint Rate on one or both control loops. You can start or stop the single SP Ramp by pressing the RUN/HOLD key. A single setpoint ramp can be configured to occur between the current local setpoint and a final local setpoint over a time interval of from 1 to 255 minutes. There is also a configurable rate of change for any local setpoint change.
Lower Display Prompt FINAL SP Upper Display Range of Setting or Selection Within setpoint limits Parameter Definition SETPOINT RAMP FINAL SETPOINT—Enter the value desired for the final setpoint. The controller will operate at the setpoint set here when ramp is ended. ATTENTION If the ramp is on HOLD, the held setpoint can be changed by the and keys. However, the ramp time remaining and original ramp rate is not changed.
Lower Display Prompt EU/HRDN2 Upper Display Range of Setting or Selection 0 to 9999 engineering units per hour Parameter Definition RATE DOWN—Rate down value for Loop 2. When making a setpoint change, this is the rate at which the controller will change from the original setpoint down to the new one. The ramping (current) setpoint can be viewed as SPn in the lower display. Entering a 0 will imply an immediate change in Setpoint (i.e., no rate applies).
4.5 Accutune Set Up Group Introduction Accutune continuously adjusts the PID parameters in response to process variable disturbances and/or setpoint changes. Also, it can be used during start-up without prior initialization or process knowledge.
Lower Display Prompt Upper Display Range of Setting or Selection ACCUTUNE for Loop 1 ACCUTUNE DISABL DISABLE —Disables the Accutune function. TUNE DEMAND TUNING—If TUNE is selected, and tuning is initiated through the operator interface or digital input (if configured), the algorithm calculates new tuning parameters and enters them into the tuning group. This tuning requires no process knowledge and does not require line out for initialization.
Lower Display Prompt KPG* Upper Display Range of Setting or Selection 0.10 to 10.00 Parameter Definition PROCESS GAIN LOOP 1—This is the Gain of the process being tuned on Loop 1. It is automatically calculated during tuning process. This is normally a READ only value. It should only need to be changed if the controller fails to identify the process. In this case, set the value to the algebraic value of PV in percent, divided by output in percent while in the manual mode.
Lower Display Prompt AT ERROR or AT ERR 2 (depending on loop) Upper Display Range of Setting or Selection Parameter Definition ACCUTUNE ERROR STATUS—When an error is detected in the Accutune process, an error prompt will appear. RUNING RUNNING—An Accutune process is still active checking process gain, even though “T” is not lit. It does not affect keyboard operation. NONE NONE—No errors occurred during last Accutune procedure.
4.6 Algorithm Data Set Up Group Introduction This data deals with various algorithms residing in the controller: • Control algorithms, • Input Math algorithms, • selecting the 1 or 2 PID Loops, • Output Override, • 2 Eight Segment Characterizers, • the Timer function, • Totalizer function, and • Gain Scheduling. ATTENTION Math option (two algorithms, two characterizers, totalizer) and Two Loops of Control are only available on Expanded Model DC330E.
Lower Display Prompt CONT ALG Upper Display Range of Setting or Selection PID A ATTENTION PID A should not be used for Proportional only action; i.e., no integral (reset) action. Instead, use PD+MR with rate set to 0. Parameter Definition PID A is normally used for three-mode control. This means that the output can be adjusted somewhere between 100 % and 0 %. It applies all three control actions— Proportional (P), Integral (I), and Derivative (D)—to the error signal.
Lower Display Prompt CONT ALG (continued) Upper Display Range of Setting or Selection 3PSTEP Parameter Definition THREE POSITION STEP—The Three Position Step Control algorithm allows the control of a valve (or other actuator) with an electric motor driven by two controller relay outputs; one to move the motor upscale, the other downscale without a feedback slidewire linked to the motor shaft. The deadband is adjustable in the same manner as the duplex output algorithm.
Lower Display Prompt Upper Display Range of Setting or Selection PID A ATTENTION PID A should not be used for Proportional only action; i.e., no integral (reset) action. Instead, use PD+MR with rate set to 0. Parameter Definition PID A is normally used for three-mode control. This means that the output can be adjusted somewhere between 100 % and 0 %. It applies all three control actions— Proportional (P), Integral (I), and Derivative (D)—to the error signal.
Lower Display Prompt TIMER Upper Display Range of Setting or Selection ENABLE DISABL Parameter Definition TIMER allows you to enable or disable the timer option. The timer option allows you to configure a timeout period and to select timer start by either the keyboard (RUN/HOLD key) or Alarm 2. A digital input can also be configured to start the timer. When the timer is enabled, it has exclusive control of the alarm 1 relay; any previous alarm configuration is ignored.
Lower Display Prompt Upper Display Range of Setting or Selection FFWDMu Parameter Definition FEEDFORWARD MULTIPLIER—Feedforward uses Input A, following a Ratio and Bias calculation as a value multiplied directly with the PID computed output value and sent, as an output value, to the final control element. (NOTE 1) The following formula applies: Controller Output = PID Output x (Input A x Ratio A + Bias A )/Input A Range RELHUM RELATIVE HUMIDITY—Input 1 reads the wet bulb temperature.
Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition CARB B CARBON POTENTIAL B—Make this selection if you have a Corning type Zirconium Oxide sensor. This algorithm requires a temperature range within the region of 1400 to 2000°F. CARB C CARBON POTENTIAL C—Make this selection if you have an A.A.C.C. type Zirconium Oxide sensor. This algorithm requires a temperature range within the region of 1400 °F to 2000 °F.
Lower Display Prompt Upper Display Range of Setting or Selection ALG1 INA ALGORITHM 1, INPUT A SELECTION will represent one of the available selections. INP 1 INP 2 LP1OUT LP2OUT IN AL1 IN AL2 INP 3 ALG1 INB Input 1 Input 2 Output 1 (NOTE 1) Output 2 Input Algorithm 1 Input Algorithm 2 Input 3 ALGORITHM 1, INPUT B SELECTION will represent one of the available selections.
Lower Display Prompt Upper Display Range of Setting or Selection INP ALG2 NONE W AVG ATTENTION F FWR2 • All Input Algorithms FFWDM2 operate in engineering A-B/C* units except FeedHI SEL forward which operates LO SEL in percent of range units. MuDIV • For General Math MULT functions, when Input C MuDIV is disabled, the value of MULT Input C used in the DEW PT functions is automatically set to 1.0. INPUT ALGORITHM 2—The selections from which to choose are listed to the left.
Lower Display Prompt PCT H2 ALG2BIAS 4/00 Upper Display Range of Setting or Selection Parameter Definition 1.0 to 99.0 (% H2) HYDROGEN CONTENT FOR DEWPOINT is only applicable when Dewpoint is selected. Enter a value for the percentage of Hydrogen content that is applicable. -999 to 9999 floating (in engineering units) INPUT ALGORITHM 2 BIAS—Does not apply to selections: FFWR2, FFWM2, HI SEL, or LO SEL.
Figure 4-1 Example of Mass Flow Compensation using Multiplier/Divider Algorithm Example - Mass Flow Compensation A gas flow rate of 650 SCFM develops a differential pressure of 90" H 2O across an orifice plate at reference conditions of 30 psig and 140 F. Compensate this gas flow for temperature and pressure variations.
Figure 4-1 Example of Mass Flow Compensation using Multiplier/Divider Algorithm, continued Example - Mass Flow Compensation Determined value of K: T 600 K 2 = 1 x ref = = 0.14914 90 Pref (90) (44.7) Therefore K = 0.386 Q SCFM = (0.386) (650) DPf (in H 2O) (IN3 + 14.7) (IN2 + 460) K (Calc HI - Calc LO ) Summary of Flow Values At Values Conditions Reference Conditions Flow (SFCM) Temp (Tf ) ( R) Pressure (T ) f (psia) DPf = 45" H 2O (50%) 140 F + 460 30 psi + 14.
Table 4-5 Lower Display Prompt Algorithm Group Definitions, Continued Upper Display Range of Setting or Selection 8SEG CH1 Parameter Definition 8 SEGMENT CHARACTERIZER #1—An eight segment characterizer can be applied to either Input 1, Input 2, Output 1, or Output 2. DISABL DISABLE—Disables characterizer. INPUT1 INPUT 1—Characterizer is applied to Input 1. INPUT2 INPUT 2—Characterizer is applied to Input 2. L1 OUT LOOP 1 OUTPUT—Characterizer is applied to Loop 1 Output.
Lower Display Prompt Upper Display Range of Setting or Selection 8SEG CH2 DISABL INPUT1 INPUT2 L1 OUT L2 OUT Parameter Definition 8 SEGMENT CHARACTERIZER #2—A second eight segment characterizer can be applied to either Input 1, Input 2, Output 1, or Output 2. DISABLE—Disables characterizer. INPUT 1—Characterizer applied to Input 1. INPUT 2—Characterizer applied to Input 2. LOOP 1 OUTPUT—Characterizer applied to Loop 1 Output. (NOTE 1) LOOP 2 OUTPUT—Characterizer applied to Loop 2 Output.
Figure 4-2 Example of Eight Segment Characterizer Y AXIS 100% N Y4 Output from Characterizer Characterizer Disabled Yn 0 0.00 0.00 1 5.00 25.00 2 10.00 37.00 3 20.00 55.00 4 31.00 70.00 5 45.00 81.00 6 60.00 87.00 7 80.00 94.50 8 99.99 99.
Table 4-5 Lower Display Prompt Algorithm Group Definitions, Continued Upper Display Range of Setting or Selection TOTALIZE Parameter Definition TOTALIZER FUNCTION calculates and displays the total flow volume as measured by Input 1 or applied to either Input Algorithm 1 or Algorithm 2 to totalize the compensated flow rate being calculated by the algorithm. Displayed value is eight digits with a configurable scale factor. DISABL INPUT1 IN AL1 IN AL2 DISABLE—Disables the totalizer function.
Lower Display Prompt Upper Display Range of Setting or Selection TOT RATE Parameter Definition TOTALIZER INTEGRATION RATE—Determines the rate at which the Totalizer is updated. SECOND MINUTE HOUR DAY ML/DAY SECOND —Engineering units per second MINUTE—Engineering units per minute HOUR—Engineering units per hour DAY —Engineering units per day MIL/DAY—Millions of units per day ATTENTION The source of the Totalizer is averaged over the sample and update rates.
4.7 Output Algorithm Parameters Set Up Group Introduction This data deals with various output types in the controller, the Digital Output Status, and the Current Duplex functionality. Output algorithm group prompts Table 4-6 lists all the function prompts in the Output Algorithm Set Up group and their definitions.
Lower Display Prompt OUT ALG (continued) Upper Display Range of Setting or Selection Parameter Definition CUR D CURRENT DUPLEX is similar to current simplex but uses a second current output. The second output is usually scaled so that zero and span correspond with 0 % and 50 % output (cool zone). When the output is 0 % to 50 %, the controller uses tuning parameter set #2, when the output is 50 % to 100 % it uses set #1.
Lower Display Prompt Upper Display Range of Setting or Selection OUT2 ALG Parameter Definition The OUTPUT ALGORITHM lets you select the type of output you want for the second control loop See OUT ALG for definitions.
4.8 Input 1 Parameters Set Up Group Introduction These are the parameters required for Input 1: actuation, transmitter characterization, high and low range values in engineering units, ratio, bias, filter, burnout, and emissivity. Input 1 group prompts Table 4-7 lists all the function prompts in the Input 1 Set Up group and their definitions.
Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition XMITTER Select one from the columns below TRANSMITTER CHARACTERIZATION—This selection lets you instruct the controller to characterize a linear input to represent a non-linear one.
Lower Display Prompt IN1 LO Upper Display Range of Setting or Selection Parameter Definition –999. To 9999. Floating (in engineering units) INPUT 1 LOW RANGE VALUE in engineering units is displayed for all inputs but can only be configured for linear or square root transmitter characterization. Scale the #1 input signal to the display value you want for 0 %. See example above. The control setpoint for Input 1 will be limited by the range of units selected here. RATIO 1 –20.00 to 20.
Lower Display Prompt EMISSIV1 4/00 Upper Display Range of Setting or Selection 0.01 to 1.00 Parameter Definition EMISSIVITY is a correction factor applied to the Radiamatic input signal that is the ratio of the actual energy emitted from the target to the energy which would be emitted if the target were a perfect radiator. Available only for Radiamatic inputs.
4.9 Input 2 Parameters Set Up Group Introduction These are the parameters required for Input 2: actuation, transmitter characterization, high and low range values in engineering units, ratio, bias, filter, burnout, and emissivity. ATTENTION Prompts for Input 2 appear only if the Input 2 PWA is installed. If the Loop1 Control Algorithm is set for PID A, PID B, or PD+MR and the Loop1 Output Algorithm is set for Position Proportional then the Input 2 configuration prompts are not displayed.
4.10 Input 3 Parameters Set Up Group Introduction These are the parameters required for Input 3: actuation, transmitter characterization, high and low range values in engineering units, ratio, bias, and filter. ATTENTION Input 3 prompts appear on expanded models only. Prompts for Input 3 only appear if Input 2 PWA is installed and the actuation for Input 2 is configured for one of the following types: 0-5 Vdc, 1-5 Vdc, 0-20 mA, or 4-20 mA.
4.11 Loop 1 Control Parameters Set Up Group Introduction The functions listed in this group deal with how the Single-Loop process controller or Loop 1 of a Two-Loop process controller will control the process including: PV source, Number of tuning parameter sets, Setpoint source, Tracking, Power-up recall, Setpoint limits, Output direction, rate and limits, Power-up preset outputs, Dropoff, Deadband, and Hysteresis.
Lower Display Prompt PID SETS (continued) Upper Display Range of Setting or Selection 2PV SW Parameter Definition TWO SETS PV AUTOMATIC SWITCHOVER—When the process variable is GREATER than the value set at prompt SW VALUE (Switchover Value), the controller will use Gain, Rate, Reset, and Cycle Time. The active PID SET can be read in the lower display. When the process variable is LESS than the value set at prompt SW VALUE, the controller will use Gain #2, Rate #2, Reset #2, and Cycle #2 Time.
Lower Display Prompt Upper Display Range of Setting or Selection RSP SRC Parameter Definition REMOTE SETPOINT SOURCE—This selection determines what your remote setpoint source will be when toggled by the SETPOINT SELECT key or Digital Input. Not available for Cascade PID Loop. RSP, Cascade, and SP3 are mutually exclusive. NONE INP 2 IN AL1 IN AL2 INP 3 NONE—No remote setpoint. INP 2—Remote Setpoint is Input 2. IN AL1—Remote Setpoint using Input 1 algorithm.
Lower Display Prompt Upper Display Range of Setting or Selection AM SP LAST MODE/LAST SETPOINT used before power down. AM LSP LAST MODE/LAST LOCAL SETPOINT on power down. PWR OUT TPSC (Three-Position Step Control) OUTPUT STARTUP MODE—This selection determines what position the motor will be in when powered up or in the failsafe position.
Lower Display Prompt OUTLoLIM Upper Display Range of Setting or Selection –5.0 to 105 % of output Parameter Definition LOW OUTPUT LIMIT—This is the lowest value of output below which you do not want the controller automatic output to exceed. Use 0 % to 100 % for digital output type. Use –5 % to 105 % for current position output. I Hi LIM* Within the range of the output limits HIGH RESET LIMIT—This is the highest value of output beyond which you want no reset to occur.
Lower Display Prompt Upper Display Range of Setting or Selection Parameter Definition MAN OUT 0 to 100 % POWER-UP PRESET MANUAL OUTPUT—At power-up, the controller will go to manual and the output to the value set here. (NOTE 1) AUTO OUT 0 to 100 % POWER-UP PRESET AUTOMATIC OUTPUT—At powerup, the controller will begin its automatic control at the output value set here.
4.12 Loop 2 Control Parameters Set Up Group Introduction The functions listed in this group deal with how Loop 2 of a Two-Loop process controller will control the process including: PV source, Number of tuning parameter sets, Setpoint source, Tracking, Power-up recall, Setpoint limits, Output direction, rate and limits, Dropoff, Deadband, and Hysteresis. Only available on Expanded Model DC330E-XX-XXX.
Lower Display Prompt PID SETS (continued) Upper Display Range of Setting or Selection 2PV SW Parameter Definition TWO SETS PV AUTOMATIC SWITCHOVER—When the process variable is GREATER than the value set at prompt SW VALUE (Switchover Value), the controller will use Gain #3, Rate #3, Reset #3, and Cycle #3 Time. The active PID SET can be read in the lower display. When the process variable is LESS than the value set at prompt SW VALUE, the controller will use Gain #4, Rate #4, Reset #4, and Cycle #4 Time.
Lower Display Prompt Upper Display Range of Setting or Selection RSP SRC Parameter Definition REMOTE SETPOINT SOURCE—This selection determines what your remote setpoint source will be when toggled by the SETPOINT SELECT NONE INP 2 IN AL1 IN AL2 INP 3 or Digital Input. NONE—No remote setpoint, INPUT 2—Remote Setpoint is Input 2. INPUT ALGORITHM 1—Remote Setpoint using Input 1 algorithm. INPUT ALGORITHM 2—Remote Setpoint using Input 2 algorithm. INP 3—Remote Setpoint is Input 3.
Lower Display Prompt Upper Display Range of Setting or Selection REVRSE OUT RATE Parameter Definition REVERSE ACTING CONTROL—The controller's output decreases as the process variable increases. OUTPUT CHANGE RATE—Enables or disables the Output Change Rate. The maximum rate is set at prompt PCT/M UP or PCT/M DN. DISABL ENABLE DISABLE—Disables output rate. ENABLE—Allows output rate.
Lower Display Prompt FAILSAFE Upper Display Range of Setting or Selection 0 to 100 % Parameter Definition FAILSAFE OUTPUT 2 VALUE—The value used here will also be the output level when you have Communications SHED set to failsafe or when NO BURNOUT is configured and input 1 fails. ATTENTION At power-up, the Loop 2 Output is set to the Failsafe Output 2 value.
4.13 Options Set Up Group Introduction Configure the remote mode switch (Digital Inputs) to a specific contact closure response, or configure the Auxiliary Output to be a specific selection with desired scaling. Option group prompts Table 4-12 lists all the function prompts in the Options Set Up group and their functions.
Lower Display Prompt AUX OUT Upper Display Range of Setting or Selection Parameter Definition DEVIATION (PROCESS VARIABLE MINUS SETPOINT)—Represents –100 % to +100 % of the selected PV span in engineering units. DEV FOR EXAMPLE: Type T Thermocouple PV range PV span Deviation Range If PV and SP then Deviation Display Auxiliary Output = = = = = = = –300 °F to +700 °F 1000 °F –1000 °F to +1000 °F 500 °F 650 °F –150 °F 42.5 % When Deviation is selected, only one operating parameter will be entered.
Lower Display Prompt AUX OUT (continued) 4mA VAL* Upper Display Range of Setting or Selection Parameter Definition CB OUT2 CONTROL BLOCK OUTPUT2—Represents the uncharacterized use of automatic control valve which allows the characterizer to characterize the output on Analog Output 1 and the Auxiliary Output to use the uncharacterized output value as Output 2.
Lower Display Prompt DIG IN 1 (continued) Upper Display Range of Setting or Selection ToHOLD Parameter Definition TO HOLD—Contact closure suspends Setpoint Program or Setpoint Ramp. When contact reopens, the controller starts from the Hold point of the Ramp/Program unless the Ramp/Program was not previously started via the RUN/HOLD key. This selection applies to either loop. ToPID2 TO PID2—Contact closure selects PID Set 2. PV 2IN PV=INPUT 2—Contact closure selects PV = Input 2.
Lower Display Prompt DIG IN 1 (continued) Upper Display Range of Setting or Selection Parameter Definition AM STA TO AUTO/MANUAL STATION—Contact closure causes the loop to perform as follows: PV = Input 2 Action = Direct Control algorithm = PD+MR PID SET = 2 SP = LSP 2 This selection is only available on Loop 1. ToTUNE INITIATE LIMIT CYCLE TUNING—Contact closure starts the tuning process. The lower display shows TUNE ON. Opening the contact has no effect.
Lower Display Prompt Upper Display Range of Setting or Selection DIG IN 1 (continued) HealthWatch option prompts: RESETT1 RESETT2 RESETT3 R ALL T RESETC1 RESETC2 RESETC3 R ALL C RALLTC DIG 1 COM DIG IN 2 DIG2 COM Parameter Definition TIMER 1 will be reset when contact closes. TIMER 2 will be reset when contact closes. TIMER 3 will be reset when contact closes. ALL TIMERS will be reset when contact closes. COUNTER 1 will be reset when contact closes. COUNTER 2 will be reset when contact closes.
4.14 Communications Set Up Group Introduction This option allows the controller to be connected to a host computer via RS-422/485 or Modbus protocol. The controller looks for messages from the computer at regular intervals. If these messages are not received within the configured shed time, the controller will SHED from the communications link and return to standalone operation. Depending on the protocol selected, the device address, parity, and baud rate are configurable.
Lower Display Prompt SHEDTIME Upper Display Range of Setting or Selection 0 to 255 Parameter Definition SHED TIME—The number that represents how many sample periods there will be before the controller sheds from communications. Each period equals 1/3 seconds; 0 equals No shed. Note: If ComSTATE is set to MODBUS or MB3K and if SHEDENAB is set to DISABL, Shed Time will not be configurable.
Lower Display Prompt Upper Display Range of Setting or Selection SHEDMODE Parameter Definition SHED CONTROLLER MODE AND OUTPUT LEVEL— Determines the mode of local control you want when the controller is shed from the communications link. Note: If COMSTATE = MODBUS or MB3K and if SHEDENAB=DISABLE, this prompt will not be configurable. LAST LAST—SAME MODE AND OUTPUT—The controller will return to the same mode (manual or automatic) at the same output level that it had before shed.
Lower Display Prompt Upper Display Range of Setting or Selection LOOPBACK Parameter Definition LOCAL LOOPBACK tests the communications hardware. DISABL DISABLE—Disables the Loopback test. ENABLE ENABLE—Allows loopback test. The UDC goes into Loopback mode in which it sends and receives its own message. The UDC displays PASS or FAIL status in the upper display and LOOPBACK in the lower display while the test is running. The UDC will go into manual mode.
4.15 Alarms Set Up Group Introduction An alarm is an indication that an event that you have configured (for example—Process Variable) has exceeded one or more alarm limits. There are two alarms available. Each alarm has two setpoints. You can configure each of these two setpoints to alarm on various controller parameters. There are two alarm output selections, High and Low. You can configure each setpoint to alarm either High or Low. These are called single alarms.
Lower Display Prompt A2S2 VAL* Upper Display Range of Setting or Selection Value in engineering units Parameter Definition ALARM 2 SETPOINT 2 VALUE—This is the value at which you want the alarm type chosen in prompt A2S2TYPE to actuate. The details are the same as A1S1 VAL. *When the associated type is configured for Alarm on Totalizer Value, the Alarm SP value represents the four lowest digits for the selected Totalizer Scale Factor. When the Totalizer value exceeds the Alarm SP, the alarm is activated.
Lower Display Prompt A1S2TYPE Upper Display Range of Setting or Selection Same as A1S1 TYPE Parameter Definition ALARM 1 SETPOINT 2 TYPE—Select what you want Setpoint 2 of Alarm 1 to represent. The selections are the same as A1S1TYPE. A2S1TYPE Same as A1S1 TYPE ALARM 2 SETPOINT 1 TYPE—Select what you want Setpoint 1 of Alarm 2 to represent. The selections are the same as A1S1TYPE. ATTENTION Not applicable with Relay Duplex or Position Proportional outputs.
Lower Display Prompt Upper Display Range of Setting or Selection AL HYST 0.0 to 100.0 % of span or full output as appropriate Parameter Definition ALARM HYSTERESIS—A single adjustable hysteresis is provided on alarms such that when the alarm is OFF it activates at exactly the alarm setpoint; when the alarm is ON, it will not deactivate until the variable is 0.0 % to 100 % away from the alarm setpoint. Configure the hysteresis of the alarms based on INPUT signals as a % of input range span.
4.16 Display Parameters Set Up Group Introduction This group includes selections for Decimal place, Units of temperature, and Power frequency. Display group prompts Table 4-15 lists all the function prompts in the Display Set Up group and their definitions. Table 4-15 Lower Display Prompt Upper Display Range of Setting or Selection DECIMAL Display Group Definitions Parameter Definition DECIMAL POINT LOCATION FOR LOOP 1—This selection determines where the decimal point appears in the display.
Lower Display Prompt Upper Display Range of Setting or Selection LANGUAGE Parameter Definition LANGUAGE—This selection designates the prompt language. ENGLISH FRENCH GERMAN SPANISH ITALIAN ENGLIS FRENCH GERMAN SPANIS ITALAN 4.17 Calibration Data Introduction The prompts used here are for field calibration purposes. Refer to Section 6 – Input Calibration in this manual for complete information. 4.18 Maintenance Group Introduction The Maintenance group prompts are part of the HealthWatch feature.
Lower Display Prompt TIME1 (continued) Upper Display Range of Setting or Selection GSOAK SOOTNG DIGIN1 DIGIN2 MAN2 HRS.MIN1 OR DAYS.HRS1 TIME 2 HRS.MIN2 OR DAYS.HRS2 TIME 3 HRS.MIN3 OR DAYS.HRS3 00.00 to 23.59 Shows elapsed time of Timer 1 in Hours and Minutes. At 24.00, units change automatically to Days and Hours. Same as TIME 1 The timer tracks the elapsed time of the selected event. 00.00 to 23.59 Shows elapsed time of Timer 2 in Hours and Minutes. At 24.
Lower Display Prompt Upper Display Range of Setting or Selection (continued) TUNE2 COUNTS1 COUNTER2 COUNTS2 COUNTER3 COUNTS3 PASSWORD Parameter Definition Failsafe mode. LOOP 2 TUNE—Number of times Loop 2 has been tuned (manually and automatically). 0-9999 (1 = 1000 counts for output relays 1 and 2) Shows the value of Counter 1. Read only. Same as COUNTER1 Counter 2 counts the number of times the selected event has occurred. Same as COUNTS1 Shows the value of Counter 2. Read only.
Section 5 – Operation 5.1 Overview Introduction This section gives you all the information necessary to monitor and operate your controller. Review the Operator Interface shown in “Monitoring” to make sure you are familiar with the indicator definitions. The key functions are listed in Section 1 – Overview. What’s in this section? This section contains the following topics: Topic 4/00 See Page 5.1 Overview 147 5.2 How to Power Up the Controller 148 5.3 Entering a Security Code 150 5.
5.2 How to Power Up the Controller Apply power When power is applied, the controller will run three diagnostic tests. All the displays will light and then the controller will go into automatic mode. Diagnostic tests Table 5-1 lists the three diagnostic tests.
Check the displays and keys Use the procedure in Table 5-2 to run the display and key test. Table 5-2 Procedure for Testing the Displays and Keys Press SET UP Result The controller will run a display test. All the displays will light for 8 seconds, then the displays will look like this: and hold in, then Upper Display keys FUNCTION LOOP 1/2 Lower Display try all at the same time Press each key to see if it When the key is pressed, the lower display will indicate the works name of the key pressed.
5.3 Entering a Security Code Introduction The LOCKOUT feature in the UDC 3300 is used to inhibit changes (via keyboard) of certain functions or parameters by unauthorized personnel. There are different levels of LOCKOUT depending on the level of security required. These levels are: NONE CALIB +CONF +VIEW MAX See Section 4 - Configuration Definitions for details. Security code numbers The level of keyboard lockout may be changed in the Set Up mode.
5.4 Monitoring Your Controller Operator interface The indicators and displays on the operator interface let you see what is happening to your process and how the controller is responding. Figure 5-1 is a view of the operator interface. A description of the displays and indicators is included.
Annunciators The following annunciator functions have been provided: A visual indication of each alarm ALM 1 2 Blinking 1 indicates alarm latched and needs to be acknowledged before extinguishing when the alarm condition ends.
Viewing the operating parameters Press the LOWER DISPLAY key to scroll through the operating parameters listed in Table 5-4. The lower display will show only those parameters and their values that apply to your specific model and the way in which it was configured. Table 5-4 Lower Display Key Parameter Lower Display Indication Description OUT OUTPUT #1—Output value is percent; for Three Position Step control, this is an estimated motor position when no slidewire exists.
Diagnostic error messages The UDC 3300 performs background tests to verify data and memory integrity. If there is a malfunction, an error message will be displayed. In the case of more than one simultaneous malfunction, only the one with the highest priority will appear on the lower display. A list of error messages is contained in Table 5-5. If any of these error messages occur, refer to Section 9 - Troubleshooting for information to correct the failure.
5.5 Start-up Procedure Procedure The Start-up procedure is given in Table 5-6. Table 5-6 Step Operation 1 Select the loop 2 Select manual mode 3 Adjust the output Procedure for Starting Up the Controller Press Action FUNCTION LOOP 1/2 to toggle between Loop 1 and Loop 2, if configured. until “MAN” indicator is ON. The controller is in manual mode. MANUAL AUTO to adjust the output value and ensure that the final control element is functioning correctly.
5.6 Operating Modes Available modes The controller can operate in any of three basic modes: • Manual—One or Two Loops • Automatic with Local Setpoint—One or Two Loops • Automatic with Remote Setpoint—One or Two Loops • Manual Cascade • Automatic Cascade The manual and automatic control modes with Local and Remote setpoint are standard with the instrument; cascade control is optional. Mode definitions Table 5-7 lists the available modes and their definitions.
What happens when you change modes Table 5-8 explains what happens to the controller when you switch from one mode to another. Table 5-8 Changing Operating Modes Mode Change Manual to Automatic Local Setpoint Description The Local Setpoint is usually the value previously stored as the Local Setpoint. PV tracking is a configurable feature which modifies this. For this configuration, when a loop is in manual mode, the local setpoint value tracks the process variable value continuously.
Selecting manual or automatic mode An alternate action switch places the controller in the Automatic or Manual mode of operation. Switching between manual and automatic will be bumpless, except when PD+MR algorithm is selected. Table 5-9 includes procedures for selecting automatic or manual mode and changing the output while in manual. Table 5-9 Step 1 Procedure for Selecting Automatic or Manual Mode Operation Selecting Automatic Mode Press MANUAL AUTO Action until “A” indicator is ON.
Position proportional backup mode This feature provides for Position Proportional models to automatically change to a Three Position Step algorithm if the slidewire input signal fails. This will maintain control of your process. “IN2 RNG” or “SW FAIL” will flash in the lower display and the “OUT” display will show an estimated motor position WITHOUT a decimal point.
5.7 Setpoints Introduction You can configure the following setpoints for the UDC 3300 controller. • A single local setpoint, • Two local setpoints, • One local setpoint and one remote setpoint, • Three local setpoints, • Two local setpoints and one remote setpoint. To scroll through the setpoint type menu, press and hold in the SETPOINT SELECT key. Release when the desired setpoint selection is displayed.
Changing local setpoint 1, 2, or 3 Use the procedure in Table 5-11 to change any of the local setpoint values. After changing a local setpoint value, if no other key is pressed, a minimum of 30 seconds time will elapse before the new value is stored in nonvolatile memory. If power is removed before this time, the new setpoint value is lost and the previous setpoint value is used at power up. If after changing the LSP value another key is pressed, then the value is stored immediately.
Enabling (or disabling) the remote setpoint Use the procedure in Table 5-12 to enable the remote setpoint source.
5.8 Setpoint Ramp Rate Configuration You can configure a Setpoint Ramp Rate that will apply to any Local setpoint change immediately. Refer to the Configuration Section to enable the ramp for either loop and set an upscale or downscale rate value. Make sure SP RAMP and SP PROG are disabled. Operation When a local setpoint change is made, the controller will ramp from the original setpoint to the new one at the rate specified. This changing (current) setpoint can be viewed as SPn on the lower display.
5.9 Single Setpoint Ramp Configuring the setpoint ramp You can configure a single setpoint ramp to occur between the current local setpoint and a final local setpoint over a time interval of from 1 to 255 minutes. You can RUN or HOLD the ramp at any time. ATTENTION The UDC 3300 has PV Hot Start functionality as standard feature. This means that at power-up Local Setpoint #1 is set to the current PV value and the Ramp, Rate, or Program then starts from this value.
Step 5 Operation Set the Final Setpoint value Press FUNCTION L1/L2 Action Upper Display Lower Display FINAL SP or The final Setpoint value to change the upper display value to the desired final setpoint value. Setting Range = within the setpoint limits 6 4/00 Exit Configuration LOWER DISPLAY To exit configuration.
Running the setpoint ramp Running a Setpoint Ramp includes starting, holding, viewing the ramp time, ending the ramp, and disabling it. Procedure Table 5-15 lists the procedure for running the Setpoint Ramp.
Step Operation 6 Change setpoint during Hold mode Press or Action to change the “HELD” setpoint if the ramp is on “HOLD.” However, the ramp time remaining is not changed. Therefore, when returning to RUN mode, the setpoint will ramp at the same rate as prior to local setpoint changes and will stop if the final setpoint is reached before time expires. If the time expires before the final setpoint is reached, it will jump to the final setpoint.
5.10 Using Two Sets of Tuning Constants Introduction You can use two sets of tuning constants for single output types and 2-loop or cascade control, and choose the way they are to be switched. (Does not apply for Duplex control.) The sets can be: • keyboard selected, • automatically switched when a predetermined process variable value is reached, • automatically switched when a predetermined setpoint value is reached.
Set switchover value If you select 2 PVSW or 2 SPSW, you must set a value at which the sets will switch over. The procedure in Table 5-17 shows you how to set this value. This procedure assumes that you are still in the Control Set Up group from Table 5-16.
Switch between two sets via the keyboard (without automatic switchover) This procedure is operational only if 2 PID SETS was configured at the Control Set Up group. The procedure in Table 5-19 shows you how to switch from one set to another. Table 5-19 Step 1 Procedure for Switching PID SETS from the Keyboard Operation Access the PID set display Press LOWER DISPLAY Action until you see: Upper Display The PV value Lower Display PIDSETX or X = 1 or 2 to change PID SET 1 to PID SET 2 or vice versa.
5.11 Alarm Setpoints Introduction An alarm consists of a relay contact and an operator interface indication. The alarm relay is de-energized if setpoint 1 or setpoint 2 is exceeded. The alarm relay is energized when the monitored value goes into the allowed region by more than the hysteresis. The relay contacts can be wired for normally open (NO) energized or normally closed (NC) de-energized at the rear terminals. See Table 2-8 in the Section 2 – Installation for alarm relay contact information.
5.12 Two Loops of Control Overview Introduction The UDC 3300 can operate using two independent loops of control or internal Cascade control. Available only on Expanded Model DC330E-XX-XXX. TWO INDEPENDENT LOOPS—See Functional Overview Block Diagrams for Loop 1 and Loop 2 (Figure 5-2) and Table 5-21 for selections based on these diagrams. The following rules apply for two independent loops: • Current output on Loop 2 requires auxiliary output.
Functional overview Figure 5-2 Figure 5-2 is a block diagram of a Loop 1 of a single loop controller and Loop 1 and Loop 2 of a dual loop controller.
Internal cascade Figure 5-3 Figure 5-3 is a block diagram of internal Cascade for a 2-loop controller.
Figure 5-4 is a block diagram of the Hi/Lo Override Selector. Figure 5-4 PV 1 PID LOOP 1 PV 2 PID LOOP 2 Hi/Lo Override Selector OUTPUT 1 OUTPUT 1 TERMINALS HI/LO OVERRIDE SELECTOR OUTPUT 2 TERMINALS OUTPUT 2 IF DESIRED 24183 Two-loop restrictions Table 5-22 Table 5-22 gives two-loop functionality and restrictions for controllers with one current output (Auxiliary output) and three relay outputs.
Two-loop restrictions Table 5-23 Table 5-23 gives two-loop functionality and restrictions for controllers with two current outputs (including Auxiliary output) and two relay outputs.
5.13 Configuring Two Loops of Control Select 2-loop algorithm The procedure in Table 5-24 shows you how select the 2-loop algorithm.
Step 3 Operation Select Loop 2 algorithms Press FUNCTION LOOP 1/2 Action until you see: Upper Display Lower Display OUT2 ALG or Select control parameters for each loop NONE TIME CURRNT CUR D CUR TI TI CUR to select Loop 2 algorithm. The procedure in Table 5-26 shows you how select the 2 loop algorithm.
Select tuning parameters for each group The procedure in Table 5-27 shows you how select the Tuning Parameters. Table 5-27 Step 1 Operation Select Tuning Set Up Group Procedure for Selecting Tuning Parameters Press SET UP Action until you see: Upper Display Upper Display SET UP SET UP Lower Display Lower Display TUNING for Loop 1 TUNING 2 or for Loop 2 PID sets 1 and 2 (TUNING) are for Loop 1 and single loop applications.
5.14 Monitoring Two Loops of Control Introduction Monitoring two individual loops of control or internal Cascade is the same as a single loop except as indicated in Table 5-28.
5.15 Operating Two Loops of Control Loop operation Operation of two individual loops of control is identical to operating a single loop of control except that TUNING 2 group applies to Loop 2 only and two PID sets, 3 and 4, are available. TUNING group applies to Loop 1 with PID sets 1 and 2 applicable. Operating modes and setpoint source The rules for Auto/Manual modes and changing setpoint sources are the same as single loop operation.
5.16 Three Position Step Control Algorithm Introduction The Three Position Step Control algorithm (Loop 1 only) allows the control of a valve (or other actuator) with an electric motor driven by two controller output relays; one to move the motor upscale, the other to move it downscale, without a feedback slidewire linked to the motor shaft. Accutune SP or SP+PV tuning does not function with this algorithm. Accutune TUNE will operate with this algorithm.
5.17 Input Math Algorithms Introduction If selected via Math options, this controller has two input algorithms available. Each algorithm can be configured to provide a derived (calculated) PV or a derived remote setpoint. Up to three inputs may be applied to the calculation. In addition, the two algorithms may be “linked” to combine two calculations by configuring one algorithm to be an input to the other algorithm.
8-segment characterization This is available as part of the Math Algorithm option. Two 8- selections can made in Section 3 – Configuration; Set Up group ALGORTHM, under function prompts: 8SEG CH1 Xn VALUE Yn VALUE 8SEG CH2 Xn VALU2 Yn VALU2 An 8-segment characterizer can be applied to either Input 1, Input 2, Output 1, or Output 2. When Input 1 or Input 2 is used, the selected input’s Ratio and Bias are applied to the Xn values.
Alarm on totalizer value The alarm type configuration includes an Alarm on Totalizer value. This allows an alarm setpoint value to be used to cause an alarm when exceeded. The alarm setpoint represents the lowest four digits of the selected Totalizer Scale Factor and has a range from 0 to 9999 x Totalizer Scale Factor. Totalizer reset via digital input The digital input type configuration includes a Reset Totalizer that resets the accumulated totalizer value when the DI is closed.
5.18 Digital Input Option (Remote Switching) Introduction The Digital Input option detects the state of external contacts for either of two inputs. On contact closure, the controller will respond according to how each digital input is configured. If the controller is configured for either 2-loop or Cascade control, then switch #1 operates only on Loop 1 and switch #2 operates only on Loop 2. Make your selection under the Option Set Up group function prompt “DIG IN1” or “DIG IN2.
DIG IN1 or DIG IN2 Selections TO RUN Display Indication Action on Contact Closure Returns (toggles) to original state when contact opens, unless otherwise noted. R indicator blinks Starts a stopped SP Program. Reopening contact puts the controller in Hold mode. This selection applies to either loop. ToBEGN Resets the Setpoint Program back to the beginning of the first segment in the program and places the program into the Hold mode. Reopening the contact has no effect.
Keyboard operation Front panel keys have no effect on the digital input action in the closed state. Digital inputs 1 and 2 combination selections The Digital Input combination selections listed in Table 5-31 can be used in combination with the digital inputs 1 and 2 listed in Table 5-30. Refer to Section 3 – Configuration and make your selections under the Options Set Up group function prompt “DIG 1 COMB” or “DIG 2 COMB.
Table 5-32 DIG IN1 DIG COMB Digital Inputs 1 and 2 Combination Action NONE Any Selection No action will occur when the digital input is active. ENABLED DISABLED The DIG IN condition will occur when the Digital Input is active. Example DIG IN1 = TO MAN DIG1 COM = DISABL Loop 1 will switch to MANUAL when digital input 1 is active. ACTION DISABLED ENABLED No action will occur when the digital input is active.
5.19 Auto/Manual Station Introduction When you select “AM STA” (auto manual station) under the Option Set Up group function prompt “DIG IN1” or “DIG IN2” (digital input option), contact closure on the selected digital input causes the controller to switch to Auto/Manual Station mode. Function As shown in Figure 5-5, State 2 is the “A/M Station mode” where the programmable logic controller (PLC) output is sent through the Auto/Manual Station.
Description The “AM STA” selection of digital input creates a repeater station when the digital input is closed. This is accomplished by a multi-selection from the digital input menu. • “ACTION” is forced as “DIRECT”. • “CONT ALG” is forced as “PD+MR”. • Active setpoint is forced to 2SP. • The PV is switched to “PV 2IN”. • The tuning parameters used are the second set of parameters.
SET FUNC Press ▲ ▼ to Enter Value or Selection Press UP to Select Set Up Group to Press Select Function Prompts 4 Algorithm CONT ALG PID A 5 Tuning RSET2MIN 50.00 GAIN2 See Note 1 Step Remarks Defines back-up control algorithm. Note 1. Set the Gain 2 equal to Input 1 Span Input 2 Span If “PB” is selected under the Control Set Up group function prompt “PBorGAIN”, set the PROP BD2 to Input 2 Span 100 x Input 1 Span 6 Options CAUTION Operation 192 RATE2MIN 0.
5.20 Fuzzy Overshoot Suppression Introduction Fuzzy Overshoot Suppression minimizes overshoot after a setpoint change or a process disturbance. This is especially useful in processes which experience load changes or where even a small overshoot beyond the setpoint may result in damage or lost product.
5.21 Accutune Introduction There are several types of Accutune from which to choose: • (TUNE) Demand Tuning—Tuning is done on demand – by pressing the LOWER DISPLAY and ▲ keys simultaneously, – by selecting prompt “TUNE” in the lower display, – via digital input. • (SP) Setpoint Tuning*—SP only tuning will continually adjust the Gain or Proportional Band (P), Reset (I), and Rate (D) tuning constants in response to setpoint changes.
Rules Table 5-34 is a list of rules for Accutune. Table 5-34 TUNE Accutune Rules and Regulations SP* Applicable Rule X TUNE On Demand tuning will work for all control algorithms except ON/OFF. Process line out is not required. X TUNE On Demand tuning works for integrating processes. X SP tuning will work only for algorithm PID a or PID B selections; i.e., it will NOT work with ON/OFF, Three Position Step, or PD+MR control algorithms.
Starting TUNE (demand) tuning After TUNE or TUN+PV has been enabled, use the procedure in Table 5-35 to start tuning. Table 5-35 Procedure for Starting TUNE (Demand) Tuning Step Action 1 Set the setpoint to the desired value. 2 Switch to Automatic mode by pressing the MANUAL/AUTO 3 Initiate Tuning by: • pressing the ▲ key. key when the lower display prompt = TUNE-OFF, • pressing the LOWER DISPLAY and ▲ keys simultaneously, or • using the digital input, if configured.
Using TUNE at start-up for duplex (heat/cool) After TUNE or TUN+PV has been enabled, use the procedure in Table 5-36 to use TUNE at start-up for duplex (heat/cool) control. Table 5-36 Procedure for Using TUNE at Start-up for Duplex Step 1 Action Heat Zone: • Adjust Local Setpoint 1 to a value within the Heat zone. • Put the controller in Automatic mode. • Press the LOWER DISPLAY and ▲ keys simultaneously to initiate Heat tuning. The output will cycle between 50 % and 100 % (or high output limit).
Using SP tuning at start-up After SP or PV+PV has been enabled, use the procedure in Table 5-37 to use SP tuning at start-up. Table 5-37 Procedure for Using SP Tuning at Start-up Step Action 1 Put the controller in manual mode by pressing the MANUAL/AUTO 2 Let the PV stabilize. 3 Adjust the setpoint to the desired value. 4 Put the controller in automatic mode by pressing the MANUAL/AUTO key. key.
Using SP tuning at start-up for duplex (heat/cool) After SP or SP+PV has been enabled, use the procedure in Table 5-38 to use SP tuning at start-up for duplex (heat/cool) control. Table 5-38 Procedure for Using SP Tuning at Start-up for Duplex Step Action 1 Put the controller into manual mode— MANUAL/AUTO 2 Heat Zone: key. • Adjust the Output to a value above 50 % and at least 5 % lower than the normal heating setpoint value. • Let the PV stabilize.
Retuning The controller will evaluate current tuning as SP changes occur. When retuning is required, the controller operates in automatic mode and identifies new tuning constants. At the point, the T appears and tuning values are entered and used until retuning occurs again. TUN+PV or SP+PV (process variable disturbance) The TUNE demand tuning or the SP tuning portions of these selections work as stated previously.
Error prompt Table 5-39 lists the Accutune error prompts and their definitions. Table 5-39 Upper Display Prompt NONE OUTLIM Accutune* Error Prompt Definitions Prompt Definition Action to Take No errors None SP Adapt step is greater than high output limit or less than low output limit • Check the output limits under Control Set Up group function prompts OUTHiLIM and OUTLoLIM in Section 3 – Configuration.
5.22 Carbon Potential Introduction Figure 5-6 shows a UDC 3300 controller being used to control the carbon potential of a furnace’s atmosphere. A carbon probe consisting of a ZrO2 sensor and a thermocouple (to measure the temperature at the sensor) provides two inputs to the controller. The microprocessor-based controller computes the atmosphere’s actual carbon potential from these two inputs and compares the computed value with the desired setpoint.
Diagram Figure 5-6 is a diagram illustrating the application of the UDC 3300 for carbon potential control. Figure 5-6 Carbon Potential Control Carbon Probe millivolts O2 Sensor T/C Input 2 Input 1 f(x) f(x) Carburizing Furnace CP % Carbon PV PID UDC 3300 Input 3— Optional Online CO Compensation % Carbon Calc. • SP • 2SP • 3SP or RSP Output CV E/P Enrichment Gas 24185 ATTENTION 4/00 • For Carbon control, set Input Algorithm 1 to the proper carbon sensor used and set the PV source to IN AL 1.
5.23 HealthWatch Introduction The HealthWatch feature puts diagnostic data at your fingertips so you can monitor vital performance status to improve your process, predict failures, and minimize downtime. Valuable data regarding maintenance and diagnostic selections can be read by operator-accessed displays. Alarms can be configured to activate when the desired threshold is reached. See Section 4.18 Maintenance for details on using the various HealthWatch timers and counters. See Section 4.
Section 6 – Setpoint Ramp/Soak Programming Option 6.1 Overview What is programming? The term “programming” is used here to identify the process for selecting and entering the individual ramp and soak segment data needed to generate the required setpoint versus time profile (also called a program). A segment is a ramp or soak function which together make up a setpoint program.
6.2 Program Contents What you will configure Basically, you will configure all the data that is relevant to each ramp and soak segment for a given setpoint versus time profile. The controller will prompt you through the sequence of segments and associated functions. Ramp segments A ramp segment is the time it will take to change the setpoint to the next setpoint value in the program. Ramps are odd number segments. Segment #1 will be the initial ramp time. Ramp time is determined in either: TIME* - Hours.
Guaranteed soak Each soak segment can have a deviation value of from 0 to ± 99 which guarantees the value for that segment. Guaranteed soak segment values >0 guarantee that the segments process variable is within the ± deviation for the configured soak time. Whenever the ± deviation is exceeded, soak timing is frozen. There are no guaranteed soaks whenever the deviation value is configured to 0; i.e.
Ramp unit This determines the engineering units for the ramp segments. The selections are: TIME = Hours.Minutes RATE = EU/MIN or EU/HR ATTENTION This selection cannot be changed while a program is in operation. ATTENTION 208 The Accutune TUNE selection will operate during setpoint programming. When it is initiated during a program, it places the program into Hold until it completes, then returns it to either Run or Hold depending what the state was before Tuning started.
6.3 Drawing a Ramp/Soak Profile Ramp/Soak Profile example Before you do the actual configuration, we recommend that you draw a Ramp/Soak profile in the space provided on the “Program Record Sheet” (Figure 6-2) and fill in the associated information. An example of a Ramp/Soak Profile is shown in Figure 6-1.
Program Record Sheet Draw your ramp/soak profile on the record sheet shown in Figure 6-2 and fill in the associated information in the blocks provided. This will give you a permanent record of your program and will assist you when entering the Setpoint data. Figure 6-2 Program Record Sheet 22625 Prompt Function Segment Value Prompt Function Segment STRT SEG Start Seg. SEG4TIME Soak Time 4 END SEG End Seg. SEG5RAMP Ramp Time 5 Soak SP 6 SEG6 SP RAMPUNIT Engr.
6.4 Entering the Setpoint Program Data Introduction The procedure listed in Table 6-1 tells you what keys to press and what prompts you will see when entering the setpoint program data. Follow the prompt hierarchy listed in Table 6-2 when selecting the functions for setpoint programming. ATTENTION Table 6-1 Step 1 Action Make sure SP RAMP and SP RATE are disabled first.
Table 6-2 Prompt Prompt Hierarchy and Available Selections Definition Value or Selection (use ▲ or ▼) (Lower Display) 212 (Upper Display) SP RAMP Setpoint Ramp Selection Selections: DISABL SP RAMP must be disabled to allow Setpoint Programming. SP RATE Setpoint Rate of Change Selections: DISABL SP RATE must be disabled to allow Setpoint Programming.
Prompt Definition Value or Selection (use ▲ or ▼) (Lower Display) SEG2 SP Segment #2 Soak Setpoint Value Enter Value: Within the Setpoint limits SEG2TIME Segment #2 Soak Duration Enter Value: 0-99hr.0-59min SEG3RAMP or SEG3RATE Segment #3 Ramp Time or Segment #3 Ramp Rate Enter Value: Ramp Time = 0-99hr:0-59min, or Ramp Rate = EU/MIN or EU/HR SEG4 SP Segment #4 Soak Setpoint Value Enter Value: Within the Setpoint limits SEG4TIME Segment #4 Soak Duration Enter Value: 0-99hr.
6.5 Run/Monitor the Program Introduction Make sure all the “SP PROG” function prompts under the Set Up group “SP RAMP” have been configured with the required data. An “H” will appear in the upper display indicating that the program is in the HOLD state. Run/monitor functions Table 6-3 lists all the functions required to run and monitor the program.
Function Press External Program Reset Result If Remote Switching (Digital Input option) is present on your controller, contact closure resets the SP Program back to the start of the first segment. “To Begin” Program cycle number is not affected. Reopening the contact has no effect and places the program in HOLD mode. The setpoint is changed to what the setpoint was when the program was first started.
Function Press Viewing the number of cycles left in the program LOWER DISPLAY Result until you see Upper Display “R” and the PV value Lower Display RECYC XX Remaining Cycles 0 to 99 This number does not include the current partially completed cycle. End Program When the final segment is completed, the “R” in the upper display either changes to “H” if configured for HOLD state, or disappears if configured for disable of setpoint programming.
SP programming tips Table 6-4 gives procedures for restarting, advancing, and changing the current segment time or setpoint of a running setpoint program. Table 6-4 Procedures for Changing a Running Setpoint Program Function Press Restarting a running SP program RUN HOLD LOWER DISPLAY Result/Action to place SP PROG into HOLD mode. until you see X RA XXX or X SK XX.XX in the lower display. until you see 1 RA XX.XX in the lower display. If the lower display already reads 1 RA XX.
218 UDC 3300 Controller Product Manual 4/00
Section 7 – Input Calibration 7.1 Overview Introduction This section describes the field calibration procedures for Input 1 and Input 2. Every UDC 3300 controller contains all input actuation ranges fully factory calibrated and ready for configuration to range by the user. However, these procedures can be implemented if the factory calibration of the desired range is not within specifications.
7.2 Minimum and Maximum Range Values Select the range values Table 7-1 You should calibrate the controller for the minimum (0 %) and maximum (100 %) range values of your particular sensor. If you have a two-input controller, calibrate each input separately. Select the Voltage or Resistance equivalent for 0 % and 100 % range values from Table 7-1. Use these value when calibrating your controller.
7.3 Preliminary Information Calibration steps Use the following steps when calibrating an input. Step Disconnect the field wiring Action 1 Find the minimum and maximum range values for your PV input range from Table 7-1. 2 Disconnect the field wiring and find out what equipment you will need to calibrate. DO NOT remove external resistor assemblies (if present). 3 Wire the calibrating device to your controller according to the Set Up wiring instructions for your particular input.
Equipment needed Table 7-2 lists the equipment you will need to calibrate the specific types of inputs that are listed in the table. You will need a screwdriver to connect these devices to your controller. Table 7-2 Equipment Needed Type of Input Equipment Needed Thermocouple Inputs (Ice Bath) • A calibrating device with ± 0.02 % accuracy for use as a signal source such as a millivolt source.
7.4 Input #1, #2, or #3 Set Up Wiring Thermocouple inputs using an ice bath Referring to Figure 7-2, wire the controller according to the procedure given in Table 7-3. Table 7-3 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath Step Action 1 Connect the copper leads to the calibrator. 2 Connect a length of thermocouple extension wire to the end of each copper lead and insert the junction points into the ice bath.
Thermocouple inputs using a precision resistor Referring to Figure 7-3, wire the controller according to the procedure given in Table 7-4. Table 7-4 Set Up Wiring Procedure for Thermocouple Inputs Using a Precision Resistor Step Action 1 Connect the copper leads to the calibrator. 2 Disconnect the cold junction resistor. 3 Install a 500-ohm precision resistor across Input 1 terminals 25 (R) and 27 (–) or Input 2 terminals 22 (R) and 24 (–). See Figure 7-3.
RTD inputs Use the copper leads and connect the calibrator to the rear terminals of Input #1 or #2. See Figure 7-4.
Radiamatic, millivolts, or volts (except 0 to 10 volts) inputs Use the copper leads and connect the calibrator to the rear terminals of Input #1, #2, or #3. See Figure 7-5.
0 to 10 volt inputs Use the copper leads and connect the calibrator to the rear terminals of Input #1 or #2. See Figure 7-6.
4 to 20 mA inputs Use the copper leads and connect the calibrator to the rear terminals of Input #1, #2, or #3. See Figure 7-7. Figure 7-7 Input 2 250Ω resistor assy Input 1 Wiring Connections for 4 to 20 mA inputs 10 1 L1 11 2 L2/N 12 3 + – 22 13 4 23 14 5 24 15 6 + – 25 16 7 26 17 8 9 27 Copper Leads – + 4 to 20 mA Source Input 3—Wire terminals as shown below.
7.5 Input #1, #2, or #3 Calibration Procedure Introduction Apply power and allow the controller to warm up for 15 minutes before you calibrate. Read “Set Up Wiring” before beginning the procedure. Make sure you have LOCKOUT set to NONE. See Section 3 – Configuration. CAUTION For linear inputs, avoid step changes in inputs. Vary smoothly from initial value to final 100 % value. Procedure The Calibration procedure for Input #1, #2, or #3 is listed in Table 7-5.
Step 3 Description Press Calibrate 100 % FUNCTION LOOP 1/2 Action You will see: Upper Display APPLY Lower Display INn SPAN n = 1, 2, or 3 Adjust your calibration device to an output signal equal to the 100 % range value for your particular input sensor. See Table 7-1 for Voltage or Resistance equivalents.
7.6 Restoring Factory Calibration How to restore it The factory calibration constants for all the input actuation types that can be used with the controller are stored in its nonvolatile memory. Thus, you can quickly restore the “Factory Calibration” for a given input actuation type by simply changing the actuation type to another type and then changing it back to the original type. See Table 7-6 for the procedure. Procedure Table 7-6 lists the procedure for restoring factory calibration.
Step Operation Press FUNCTION LOOP 1/2 Action/Result until the lower display rolls through the rest of the functions and returns to Upper Display New Selection Lower Display IN nTYPE or n = 1, 2, or 3 until you change the input selection in the upper display back to the proper selection. You will see: Upper Display Lower Display IN nTYPE Original input selection that matches your type of sensor. n = 1, 2, or 3 3 Return to normal operating mode LOWER DISPLAY to return to Normal operating mode.
Section 8 – Output Calibration 8.1 Overview Introduction This section describes the field calibration procedures for the following types of outputs: • Current Output • Position Proportional and 3 Position Step Output • Auxiliary Output What’s in this section This section contains the following topics: Topic See Page 8.1 Overview 233 8.2 Current Proportional Output Calibration • Introduction • Equipment Needed • How to Connect the Calibrator • Calibration Procedure 234 234 234 234 235 8.
8.2 Current Proportional Output Calibration Introduction Calibrate the controller so that the output provides the proper amount of current over the desired range. The controller can provide an output current range of from 0 to 21 milliamperes and can be calibrated at 4 mA for 0 % of output and 20 mA for 100 % of output or any other values between 0 mA and 21 mA. Equipment needed You will need a standard shop type milliammeter, with whatever accuracy is required, capable of measuring 0 to 20 milliamps.
Procedure The procedure for calibrating the Current Proportional Output is listed in Table 8-2. Make sure LOCKOUT in the Tuning Set Up group is set to NONE. See Section 3 – Configuration.
8.3 Position Proportional and Three Position Step Output Calibration Position proportional control When the UDC 3300 controller has a Position Proportional control output, calibrate the controller so that the increase and decrease relays operate properly with respect to the position of the external feedback slidewire.
Procedure The procedure for calibrating the Position Proportional output and 3 Position Step control output is listed in Table 8-3. Make sure LOCKOUT in Tuning Set Up group is set to NONE. See Section 3 – Configuration. For Three Position Step Control Output models without Motor Position Indication, do steps 1 and 2 only. For Position Proportional Output and Three Position Step Control Output models with Motor Position Indication, follow the entire calibration procedure.
Step Description Press or Action to select automatic or manual calibration. Upper Display Lower Display POS PROP DO AUTO or DO MAN If you select… DO AUTO DO MAN Then… go to Step 4 go to Step 6 ATTENTION When calibration is terminated, this selection reverts to DISABL. 4 DO AUTO Set 0 % value FUNCTION LOOP 1/2 The decrement relay is turned on to move the motor to 0 % position.
Step Description Press or Action until the desired span value is reached in the upper display. Upper Display Lower Display The desired span value SPAN VAL For manual calibration, the motor does not move from its position prior to the start of Position Proportional calibration. 8 Exit the Calibration Mode FUNCTION LOOP 1/2 LOWER DISPLAY The controller will store the 100 % value. To exit the calibration mode.
8.4 Auxiliary Output Calibration Introduction Calibrate the controller so that the Auxiliary output provides the proper amount of current over the desired range. The controller can provide an auxiliary output current range of from 0 to 21 milliamperes and can be calibrated at 4 mA for 0 % of output and 20 mA for 100 % of output or any other values between 0 mA and 21 mA.
Procedure The procedure for calibrating the Auxiliary Output is listed in Table 8-5. Make sure LOCKOUT in the Tuning Set Up group is set to NONE. See Section 3 – Configuration.
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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.
Installation related problems Read the Installation section in this manual to make sure the UDC 3300 has been properly installed. The installation section provides information on protection against electrical noise, connecting external equipment to the controller, and shielding and routing external wiring. ATTENTION System noise induced into the controller will result in diagnostic error messages recurring.
9.2 Troubleshooting Aids Overall error messages An error message can occur • at power-up, • during continuous background tests while in normal operation, • when the Status Tests are requested. Table 9-1 lists all the error message prompts that you could see, the reason for the failure, and under what test group the prompt could appear. Refer to Tables 9-3 (Power-up), 9-5 (Status), and 9-6 (Background) for the particular test group indicated.
Controller failure symptoms Other failures may occur that deal with the Power, Output, or Alarms. Refer to the controller failure symptom in Table 9-7 to determine what is wrong and the troubleshooting procedures to use to correct the problem. Check Installation If a set of symptoms still persists, refer to Section 2 - Installation and ensure proper installation and proper use of the controller in the system.
9.3 Power-up Tests What happens at power-up When the controller is powered-up, three tests are run by the UDC 3300 software to ensure memory integrity. As the tests are run, the displays will appear as shown in Table 9-3.
9.4 Status Tests Introduction When required, the results of these tests can be checked to determine the reason the controller has gone to Failsafe. How to check the status tests The procedure in Table 9-4 tells you how to display the results of the status tests. Table 9-5 lists the tests, the reason for the failure, and how to correct the problem.
Status Tests Table 9-5 lists the Status tests, the reason for their failure, and how to correct the failure. Table 9-5 Test (Lower Display) Definition FAILSAFE Failsafe Fault FAILSF2 (Loop 2) RAM TEST CONF TEST RAM test run at power-up Configuration Checksum Upper Display Status Tests Reason for Failure How to Correct the Failure NO No Failure YES Burnout configured for none and input fails. –RAM TEST failed –CONFTEST failed –CALTEST failed 1.
9.5 Background Tests Introduction The UDC 3300 performs on-going background tests to verify data and memory integrity. If there is a malfunction, an error message will be displayed (blinking) in the lower display. Background tests In the case of more than one simultaneous malfunction, only the one with the highest priority will appear in the lower display. Table 9-6 lists these background tests, the reason for their failure, and how to correct the problem.
Lower Display INP1 RNG Reason for Failure Input 1 out of range. The process input is outside the range limits. How to Correct the Problem 1. Make sure the range and actuation are configured properly. 2. Check the input source. 3. Restore the factory calibration. (See Section 7.6.) 4. Field calibrate. See Section 7 - Input Calibration. INP2 RNG Input 2 out of range. The remote input is outside the range limits. Same as INP1 RNG above. INP3 RNG Input 3 out of range.
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.
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. 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.
Procedure #2 Table 9-9 explains how to troubleshoot Current Proportional Output failure symptoms. Table 9-9 Step 1 Troubleshooting Current Proportional Output Failure What to do Make sure the controller is configured for Current output. How to do it Make Algorithm Set Up group function prompt OUT ALG or OUT2 ALG = CURRNT. Refer to Section 3 - Configuration. 254 2 Check the field wiring. Output impedance must be less than or equal to 1000 ohms.
Procedure #3 Table 9-10 explains how to troubleshoot Position Proportional Output failure symptoms. Table 9-10 Troubleshooting Position Proportional Output Failure Step What to do How to do it 1 Make sure the controller is configured for Position Proportional output. Make Output Algorithm Set Up group function prompt OUT ALG = POSITN. 2 Check the field wiring. Refer to Section 2 - Installation for Position Proportional Wiring information. 3 Check the output.
Procedure #4 Table 9-11 explains how to troubleshoot Time Proportional Output failure. Table 9-11 Step 1 Troubleshooting Time Proportional Output Failure What to do Make sure the controller is configured for Time Proportional output. How to do it Make Output Algorithm Set Up group function prompt OUT ALG = TIME or TIME D or function prompt OUT2 ALG = TIME. Refer to Section 3 - Configuration. 2 Check the field wiring. Make sure the NO or NC contact wiring is correct at the rear terminals.
Procedure #5 Table 9-12 explains how to troubleshoot Current/Time or Time/Current Proportional Output failure. Table 9-12 Step 1 Troubleshooting Time/Current or Current/Time Proportional Output Failure What to do Make sure the controller is configured for Time/Current or Current/Time Proportional output. How to do it Make Output Algorithm Set Up group function prompt OUT ALG or OUT2 ALG = TI CUR or CUR TI. Refer to Section 3 - Configuration. 2 Check the field wiring.
Procedure #6 Table 9-13 explains how to troubleshoot Alarm Relay Output failure. Table 9-13 Troubleshooting Alarm Relay Output Failure Step What to do 1 Check the alarm configuration data. If it is correct, check the field wiring. Reconfigure if necessary. Refer to Section 3 - Configuration for details. 2 Check that the applicable alarm relay actuates properly depending on what you have set at prompt AxSxTYPE. If the alarm type is set for PV, place the controller in manual mode.
Procedure #7 Table 9-14 explains how to troubleshoot a Keyboard failure. Table 9-14 Step Troubleshooting a Keyboard Failure What to do How to do it 1 Make sure the keyboard is connected properly to the MCU/output and power/input boards. 2 Controller Keyboard or specific keys Use your four-digit security code number to change the lockout level. may be LOCKED OUT via the Refer to Section 3 – Configuration. security code. Withdraw the chassis from the case and visually inspect the connection.
Procedure #8 Table 9-15 explains how to troubleshoot a Communications failure. Table 9-15 Step Troubleshooting a Communications Failure What to do How to do it 1 Check the field wiring and termination resistor. Depending on the protocol used, refer to the proper communications manual installation section. 2 Make sure the Communications Printed Wiring Board is installed properly in the controller. Withdraw the chassis from the case and inspect the board.
9.8 Parts Replacement Procedures Introduction These procedures tell you how to access and replace the following printed wiring boards in your controller.
How to remove the chassis Refer to Figure 9-1 for steps and follow the procedure listed in Table 9-16. Table 9-16 How to Remove the Chassis Step Action 1 Loosen the screw on the front face. 2 Insert a flat-bladed screwdriver into the hole on the top of the case as shown in Figure 9-1 and pry chassis forward slightly until the chassis connectors separate from the back of the case. 3 Grasp the bezel and pull the chassis out of the case.
How to replace the display/keyboard assembly Refer to Figure 9-2 and follow the procedure listed in Table 9-17. Table 9-17 Display/Keyboard Assembly Replacement Procedure Step Action 1 Remove the chassis from the case as shown in Figure 9-1. 2 Peel the rubber bezel and display window off the chassis assembly. 3 Separate the chassis frame at the four release points shown in Figure 9-2 and wiggle each printed wiring board out of its socket on the display/keyboard assembly. Pull out slightly.
How to remove the printed wiring boards from the chassis To remove the printed wiring boards from the chassis, refer to Figure 9-3 and follow the procedure in Table 9-18. Table 9-18 Printed Wiring Board Removal from Chassis Step Action 1 Remove the chassis from the case as shown in Figure 9-1. 2 Separate the chassis frame at the release points shown in Figure 9-3 and wiggle each printed wiring board out of its socket on the display/keyboard assembly. Pull both boards out of the chassis assembly.
Printed wiring board identification Figure 9-4 identifies each of the printed wiring boards that can be replaced. Refer to this drawing when following the replacement procedures for each of the boards, since you have to remove all of them from the chassis to replace the one you want. In order to lay boards flat, remove the transformer lead from the Auxiliary Output/Communications board and the Digital Input board. Refer to the specific procedure table to remove the desired board.
2nd input board Follow the procedure listed in Table 9-19 to replace the Second Input board—P/N 30756715-501. Table 9-19 Second Input Board Replacement Procedure Step Power input board Action 1 Remove the chassis from the case. See Figure 9-1. 2 Remove the printed wiring boards from the chassis. See Figure 9-3. 3 Lay the boards flat and identify the 2nd Input board. See Figure 9-4. 4 Remove the transformer plug from connector J14.
Digital input board Follow the procedure listed in Table 9-21 to replace the Digital Input board—P/N 30756696-501. Table 9-21 Step 4/00 Digital Input Board Replacement Procedure Action 1 Remove the chassis from the case. See Figure 9-1. 2 Remove the printed wiring boards from the chassis. See Figure 9-3. 3 Lay the boards flat and identify the Digital Input board. See Figure 9-4. 4 Remove the transformer plug from connector J9.
Aux.Out/ communications board Follow the procedure listed in Table 9-22 to replace the following boards: • Auxiliary Output Board—P/N 30756687-501 • Auxiliary Output/RS422/485 Board—P/N 30756687-502 • DMCS Communications Board—P/N 30756690-502 • RS422/485 Communications Board—P/N 30756693-502 (Basic) or P/N 30756693-503 (Expanded) Table 9-22 Step 268 Aux.Out/Communications Board Replacement Procedure Action 1 Remove the chassis from the case. See Figure 9-1.
MCU/output board Follow the procedure listed in Table 9-23 to replace the following MCU/output boards: Basic • Current Output—P/N 51309401-504 • Relay Output—P/N 51309401-505 Expanded • Current Output—P/N 51309401-504 • Relay Output—P/N 51309401-505 Table 9-23 MCU/Output Board Replacement Procedure Step 4/00 Action 1 Remove the chassis from the case. See Figure 9-1. 2 Remove the printed wiring boards from the chassis. See Figure 9-3. 3 Lay the boards flat and identify the MCU/Output board.
9.9 Maintenance Cleaning 270 If you find it necessary to clean the elastomer bezel, use mild soapy water.
Section 10 – Parts List 10.1 Exploded View Introduction Figure 10-1 is an exploded view of the UDC 3300 Controller. Each part is labeled with a key number. The part numbers are listed by key number in Table 10-1. There is a list of parts not shown in Table 10-2.
Parts identification Table 10-1 lists the part numbers for the key numbers shown in the exploded view.
Section 11 – Appendix A – Manual Tuning 11.1 Overview Introduction When you tune a controller, there are some things to consider: • Process Characteristics - Gain, Time Constants, etc. • Desired response - Minimal overshoot Basically, controller tuning consists of determining the appropriate values for the Gain (PB), Rate (Derivative), and Reset (Integral) time tuning parameters (control constants) that will give the control you want.
11.2 Time, Position, or Current Proportional Simplex Control Procedure The procedure listed in Table 11-1 gives you the steps for manually tuning a controller with Time, Position, or Current proportional simplex control. Table 11-1 Manual Tuning Procedure for Simplex Control Step Action 1 In Manual Mode, adjust the output to bring the PV (Process Variable) near the desired value. 2 Set the Rate time to 0 minutes and set the Reset time to the maximum value (50.
Step Action 10 Enter the values of GAIN (or PB), RATE, and RESET in minutes (or repeats per minute) into the UDC 3300 controller and verify that the PV response is adequate. Make additional trimming adjustments, if necessary, to fine tune the controller per the guidelines shown below: TO REDUCE OVERSHOOT Less Gain (more PB) perhaps a longer Rate time. TO INCREASE OVERSHOOT OR INCREASE SPEED OR RESPONSE More Gain (less PB), perhaps shorter Rate time.
11.3 Time Proportional Duplex or Current Proportional Duplex Control Introduction For HEAT/COOL applications. Tune the controller with the output above 50% for Heat and below 50% for Cool. HEAT/COOL prompts The “TUNING” function prompts for HEAT/COOL are: HEAT PB or GAIN RSETMIN or RSETRPM RATEMIN CYCSEC COOL GAIN2 RSET2MIN or RSETRPM2 RATE2MIN CYC2SEC 11.
Index Current output/ universal output connections, 26 Current proportional duplex, 276 Current simplex, 109 Current/time duplex, 110 Cycle time (cool), 81 Cycle time (heat), 81 % % Oxygen control, 203 A Aborting PV adaptive tuning, 200 Accutune, 181 Accutune, 194 Accutune error prompts, 201 Accutune Set Up group, 47 Accutune Set Up Group, 88 Adaptive tune, 89 Adaptive tune error status, 91 Advancing a running SP program, 217 Alarm blocking, 142 Alarm on totalizer value, 185 Alarm setpoints, 171 Algorithm
Index Mounting method, 14 Mounting procedure, 14 Multiplier, 97 Multiplier divider, 97 Multiplier divider with square root, 97 Multiplier with square root, 97 G Gain, 80 Gain 2, 81 Gain scheduling, 119 Gain Value for Gain Scheduling, 83 grounding, 15 Guaranteed soak, 207 O Open Collector Output Connections, 25 Operating limits, 8 Operating parameters, 153 Operation of two-loop control, 181 Operator interface, 3 Options Set Up Group, 129 Output algorithm, 109, 111 Output change rate, 121, 127 Output overri
Index Relay Output, 22 Remote mode switching, 181 Remote setpoint, 162 Remote setpoint source, 120, 126 Remote switching, 186 Reset, 81 Reset 2, 81 Reset totalizer value, 187 Reset units, 123 Restarting a running SP program, 217 Restoring factory calibration, 231 Restrictions for two-loop control, 175 Reverse acting control, 121, 127 RS422/485 Communications board, 268 Run/Hold key lockout, 82 Run/monitor SP program, 214 T, U, V Three Position Step, 94 Three Position Step Control algorithm, 182 Time duplex
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