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Honeywell UDC3300 Product Manual

Honeywell UDC3300 Product Manual

Universal digital limit controller
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UDC3300
Universal Digital
Limit Controller
51-52-25-101
1/01

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Summary of Contents for Honeywell UDC3300

  • Page 1 UDC3300 Universal Digital Limit Controller 51-52-25-101 1/01...
  • Page 2 To find information quickly, use the comprehensive Table of Contents in the front of the manual and the Index located in the back of the manual. UDC3300 Limit Controller Product Manual 1/01...
  • Page 3 Chassis Ground. Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 4: Table Of Contents

    How to Operate Your Limit Controller ............49 How to Monitor Your Limit Controller ............52 Alarm Setpoints...................54 Restarting After Power Loss ...............55 SECTION 6 – INPUT CALIBRATION ................57 Overview .....................57 Minimum and Maximum Range Values ............58 Preliminary Information ................59 UDC3300 Limit Controller Product Manual 1/01...
  • Page 5 SECTION 9 – APPENDIX A – HOW TO APPLY DIGITAL INSTRUMENTATION IN SEVERE ELECTRICAL NOISE ENVIRONMENTS........95 Overview ....................95 Potential Noise Sources ................96 Prevention Methods ................... 97 Recommended Wiring Practices ..............98 Power Source Considerations..............100 Noise Suppression at the Source ............. 101 1/01 UDC3300 Limit Controller Product Manual...
  • Page 6 Digital Input Connections.................16 Figure 2-9 RS422/485 Communications Option Connections ........17 Figure 2-10 DMCS Communications Option Connections..........18 Figure 3-1 Overview of UDC3300 Prompt Hierarchy..........20 Figure 5-1 Operator Interface ...................49 Figure 6-1 Input #1 Wiring Terminals................59 Figure 6-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath ....61...
  • Page 7 MCU/Output Board Replacement Procedure.......... 91 Table 8-1 Parts Identification................... 94 Table 8-2 Parts Not Shown ..................94 Table 9-1 External Wiring..................98 Table 9-2 MOV Devices ..................101 Table 9-3 Coil Voltage vs Resistor Voltage Rating..........102 1/01 UDC3300 Limit Controller Product Manual...
  • Page 8 MOVs....................Metal Oxide Varistors NC........................ Normally closed NO ........................Normally open RC....................Resistance-capacitance RFI ...................Radio frequency interference RH......................Relative Humidity RS422...................Communications Protocol RTD ................. Resistance Thermometer Device SCRs ................... Silicon controlled rectifiers UDC .................... Universal Digital Controller viii UDC3300 Limit Controller Product Manual 1/01...
  • Page 9 PV LIMIT ....................PV Out of Range PWR FREQ..................Power Line Frequency RAM TEST ....................RAM test failed SHEDTIME......................Shed Time SP HILIM....................High Setpoint Limit SP LOLIM....................Low Setpoint Limit UNITS ....................Communication Units XMITTER .................Transmitter Characterization 1/01 UDC3300 Limit Controller Product Manual...
  • Page 10 UDC3300 Limit Controller Product Manual 1/01...

  • Page 11: Section 1 - Overview

    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 UDC3300 is an ideal controller for limiting temperature and other process variables in numerous heating and cooling applications, in metal working, food, and pharmaceuticals, and testing and environmental work.
  • Page 12 30 meters (98 feet) to the antenna(e). In special cases, when highly susceptible apparatus is used in close proximity, the user may have to employ additional mitigating measures to further reduce the electromagnetic emissions of this equipment. UDC3300 Limit Controller Product Manual 1/01...

  • Page 13: Operator Interface

    - °Fahrenheit being used - °Centigrade being used Indicator definition when lit - Alarm conditions exist - Digital Input active LOWER RESET FUNCTION DISPLAY Keys - See Table 1-1 SET UP 22642 Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 14: Table 1-1 Function Of Keys

    • Increases the setpoint, output, or configuration values displayed. • Decreases the setpoint, output, or configuration values displayed. UDC3300 Limit Controller Product Manual 1/01...

  • Page 15: Section 2 - Installation

    Section 2 – Installation Overview Introduction Installation of the UDC3300 Limit 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.

  • Page 16: Table 2-1 Operating Limits

    20 to 27 Vac 50/60 Hz 20 to 27 Vdc 0 Hz Power Consumption 18 VA maximum (90 to 264 Vac) 12 VA maximum (24 Vac/dc) Frequency 48 to 52 Hz (For Vac) 58 to 62 Hz UDC3300 Limit Controller Product Manual 1/01...

  • Page 17: Model Number Interpretation

    3 – = T/C, RTD, Radiamatic, mV, 0-5V, 1-5V, 0-20 mA, 4-20 mA, 0-10V *FM approved Limit Controllers are restricted to thermocouple and RTD PV inputs. Limit Controllers are UL recognized for regulatory use only. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 18: Mounting

    -0.0 3.622 +0.03 -0.0 LOWER FUNCTION RESET DISPLAY SET UP Max Panel 2.4 with optional Max (2) .945 Thickness .093 rear cover .394 90.7 3.57 21.6 .850 147.3 22716 5.82 Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 19: Figure 2-3 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 UDC3300 Limit controller. Figure 2-3...

  • Page 20: Wiring

    • Input signal wire (thermocouple, 4 to 20 mA, etc.) • Digital input signals • Communications • Low voltage alarm relay output wiring • Low voltage wiring to solid state type control circuits Continued on next page UDC3300 Limit Controller Product Manual 1/01...
  • Page 21 Wiring Requirements Figure Composite Wiring Diagram Line Power 90–264 Vac or 24 Vac/dc 2–5 Input #1 Wiring 2–6 Output and Alarm Wiring Digital Inputs Wiring 2–8 Communications Wiring • RS422 2–9 • DMCS 2–10 1/01 UDC3300 Limit Controller Product Manual...

  • Page 22: Wiring Diagrams

    Wiring Diagrams Composite wiring Figure 2-4 is a composite wiring diagram of the UDC3300 Limit diagram controller. It identifies the terminal designations and their functions. Refer to the individual diagrams listed to wire the controller according to your requirements. Figure 2-4...

  • Page 23: Figure 2-5 Line Voltage Wiring

    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 90-264 V; or 1 A, 125 V fuse or circuit breaker for 24 Vac/dc operation, as part of the installation. Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 24: Figure 2-6 Input #1 Connections

    These items must be installed when you wire the controller before startup. 2 When installing the cold junction (Part number 30757088-001) for a T/C input, remove the screws from terminals 25 and 27, and install the assembly into place. Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 25: Figure 2-7 Output And Alarm Wiring

    Non-Latching N.O. Power To terminal 7 or 9 Electromechanical relays are rated at 5 Amps @ 120 Vac or 2.5 Amps at 240 Vac. Customer should size fuses accordingly. 22645 Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 26: Figure 2-8 Digital Input Connections

    Figure 2-8 Digital Input Connections Digital Input Switch #1 Connect shield to ground at one end only L2/N Switch Common 22646 Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 27: Figure 2-9 Rs422/485 Communications Option Connections

    To Other lines in the same Communication Use shielded twisted pair cables conduit as AC power (Belden 9271 Twinax or equivalent) Instruments 120 Ohm Resistor (maximum 15) on Last Leg 22621 Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 28: Figure 2-10 Dmcs Communications Option Connections

    Do not run these lines in the same conduit as AC power To Other Communication Use shielded twisted pair Instruments cables (Belden 9271 120 Ohm Resistor Twinax or equivalent) (Maximum 31) on Last Leg 22622 UDC3300 Limit Controller Product Manual 1/01...

  • Page 29: Section 3 - Configuration

    As you will see, the configuration data is divided into 5 main Set Up groups plus prompts for calibration and prompts that show the status of the continuous background tests that are being performed. Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 30: Configuration Prompts

    Configuration Prompts Diagram: prompt Figure 3-1 shows an overview of the UDC3300 Set Up prompts and their hierarchy associated Function prompts. Read from left to right. Figure 3-1 Overview of UDC3300 Prompt Hierarchy • Press [SET UP] key to access the Set Up prompts.

  • Page 31: How To Get Started

    Located on the last page of this section is a “Configuration Record sheet Sheet”. When you make your configuration selections, record them on this sheet. Then you will have a record of how the controller was configured. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 32: Configuration Tips

    • parameter not available • not in Set Up mode, press [SET UP] key first • key malfunction, do keyboard test (operation) UDC3300 Limit Controller Product Manual 1/01...

  • Page 33: Configuration Procedure

    Upper Display FUNCTION Lower Display SECURITY Shows the first Function prompt within that Set Up group. Example displays show Set Up group “Lockout”, Function prompt “Security” and the code selected. Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 34: Table 3-2 Configuration Procedure

    Exit Configuration This exits configuration mode and returns the controller LOWER to the same state it was in immediately preceding entry DISPLAY into the Set Up mode. It stores any changes you have made. UDC3300 Limit Controller Product Manual 1/01...

  • Page 35: Lockout Set Up Group

    Table 3-3 Lockout Group Function Prompts Function Prompt Function Selections or Factory Lower Display Name Range of Setting Setting Upper Display SECURITY Security Code 0 to 4095 LOCKOUT Configuration Lockout NONE NONE CALIB +CONF 1/01 UDC3300 Limit Controller Product Manual...

  • Page 36: Limit Set Up Group

    1000 units ATTENTION This value should never be set higher than the temperature limit of the oven or furnace being controlled. SP LOLIM Low Setpoint Limit 0 to 100% of Span in engineering units UDC3300 Limit Controller Product Manual 1/01...

  • Page 37: Input 1 Parameters Set Up Group

    Value (Linear Inputs and in engineering units (2400 for FM only) Radiamatic RI only) IN1 LO Input 1 Low Range –999. to 9999. Value (Linear Inputs and in engineering units Radiamatic RI only) Continued on next page 1/01 UDC3300 Limit Controller Product Manual...
  • Page 38 Burnout is fixed. UPSCALE for FM For non-linear inputs: High Limit Control = Upscale Low Limit Control = Downscale EMISSIV Emissivity 0.01 to 1.00 PWR FREQ Power Line Frequency 60 Hz 60 Hz 50 Hz UDC3300 Limit Controller Product Manual 1/01...

  • Page 39: Communications Set Up Group

    (RS422/485 Only) 1200 19200 2400 DUPLEX Duplex Operation HALF HALF FULL (RS422/485 Only) TX DELAY Transmission Delay 1 to 500 milliseconds (RS422/485 Only) LOOPBACK Local Loop Back DISABL DISABL ENABLE UNITS Communication Units PERCNT 1/01 UDC3300 Limit Controller Product Manual...

  • Page 40: Alarms Set Up Group

    Alarm 1, Setpoint 2 State A2S1 H L Alarm 2, Setpoint 1 State A2S2 H L Alarm 2, Setpoint 2 State AL HYST Alarm Hysteresis 0.0 to 5.0% of Span or 100% Output, as appropriate UDC3300 Limit Controller Product Manual 1/01...

  • Page 41: Calib Group

    Status Group Status Test Data The prompts used here are read only. They are used to determine the reason for a controller failure. Refer to Section 7 – Troubleshooting in this manual for complete information. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 42: Configuration Record Sheet

    A2S1TYPE __________ BURNOUT Upscale None __________ A2S2TYPE __________ EMISSIV None __________ A1S1 H L __________ PWR FREQ 60Hz __________ A1S2 H L __________ A2S1 H L __________ A2S2 H L __________ AL HYST __________ UDC3300 Limit Controller Product Manual 1/01...

  • Page 43: Section 4 - Configuration Prompt Definitions

    Contents See Page Overview Lockout Data Set Up Group Limit Data Set Up Group Input 1 Set Up Group Communications Set Up Group Alarms Set Up Group Calibration Data Status Test Data 1/01 UDC3300 Limit Controller Product Manual...

  • Page 44: Lockout Data Set Up Group

    UNTIL ALL CONFIGURATION IS COMPLETE. NONE No Lockout—all groups read/write. CALIB CALIB—All are available for read/write except for the Calibration group. +CONF +CONF—All groups are read only. MAX—Only Lockout group is available. No other parameters are viewable. UDC3300 Limit Controller Product Manual 1/01...

  • Page 45: Limit Data Set Up Group

    SETPOINT LOW LIMIT—This selection prevents the input in engineering units setpoint from going below the value selected here. The with decimal place setting must be equal or greater than the lower range of input 1. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 46: Input 1 Parameters Set Up Group

    UNITS TEMPERATURE UNITS—This selection will be indicated on the annunciator. What display of temperature do you want. DEG F DEG C Degrees Fahrenheit NONE Degrees Celsius None Continued on next page UDC3300 Limit Controller Product Manual 1/01...
  • Page 47 0 to 10 Millivolts* 0-50mV 0 to 50 Millivolts* 0-5 V 0 to 5 Volts* 1-5 V 1 to 5 Volts* 0-10 V 0 to 10 Volts* *not available for FM models Continued on next page 1/01 UDC3300 Limit Controller Product Manual...
  • Page 48 100 LO 100 Ohm RTD low 200 PT 200 Ohm–RTD 500 PT 500 Ohm–RTD RAD RH Radiamatic (Type RH) RAD RI Radiamatic (Type RI) LINEAR Linear Range SQROOT Extracts Square Root Continued on next page UDC3300 Limit Controller Product Manual 1/01...
  • Page 49 Available only for “Radiamatic” inputs. PWR FREQ POWER LINE FREQUENCY—select whether your controller is operating at 60 Hz or 50 Hz. 60 Hz 60 HERTZ 50 HERTZ 50 Hz 1/01 UDC3300 Limit Controller Product Manual...

  • Page 50: Communications Set Up Group

    BAUD RATE is the transmission speed in bits per second. (RS422/485 only) 300 BAUD 600 BAUD 1200 1200 BAUD 2400 BAUD 2400 4800 BAUD 4800 9600 BAUD 9600 19200 BAUD 19200 Continued on next page UDC3300 Limit Controller Product Manual 1/01...
  • Page 51 The test will run until the operator disables it here. DISABL DISABLE—disables the Loopback test. UNITS COMMUNICATION UNITS—This selection determines how the controller values are expressed during communications. PERCNT PERCENT OF SPAN ENGINEERING UNITS 1/01 UDC3300 Limit Controller Product Manual...

  • Page 52: Alarms Set Up Group

    Deviation or Input 1, and if you have a model with communications, you can configure the controller to alarm on SHED. NO ALARM NONE INPUT 1 DEVIATION SHED FROM COMMUNICATIONS SHED Continued on next page UDC3300 Limit Controller Product Manual 1/01...
  • Page 53 ON, it will not deactivate until the variable is 0.0% to 5.0% away from the alarm setpoint. Configure the hysteresis of the alarms based on INPUT signals as a % of input range span. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 54: Calibration Data

    6 – Calibration in this manual for complete information. Status Test Data Introduction The prompts used here are for determining the reason for a controller failure. Refer to the Section 7 – Troubleshooting in this manual for complete information. UDC3300 Limit Controller Product Manual 1/01...

  • Page 55: Section 5 - Operation

    Digital Input Option How to Reset the Latching Relay How to Monitor Your Limit Controller Diagnostic Error Messages RS422 Communications DMCS Communications Alarm Setpoints Introduction Displaying or Changing the Alarm Setpoints Restarting After a Power Loss 1/01 UDC3300 Limit Controller Product Manual...

  • Page 56: How To Power Up The Controller

    If one or more of these tests fail, the controller will go to the Failsafe Mode, and “FAILSAFE” will flash in the lower display. Troubleshooting Refer to “STATUS TESTS” in Section 7 — Troubleshooting to identify and correct the problem. Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 57: Table 5-2 Procedure For Testing The Displays And Keys

    When a key is pressed and the prompt “KEY ERROR” appears in the lower display, it will be for one of the following reasons: • parameter not available, • not in Set Up mode, press [SET UP] key first, • key malfunction, do keyboard test. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 58: Enter A Security Code

    Enter a Security Code Introduction The LOCKOUT feature in the UDC3300 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:...

  • Page 59: How To Operate Your Limit Controller

    When a single decimal position has been configured and values greater than 1000 are displayed, the right-most character is blank but the decimal point will be lit. Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 60: Table 5-4 Limit Action Duration Or Peak Pv Value

    How to Operate Your Limit Controller, Continued Operating principles The UDC3300 Limit Controller accepts signals from such sources as thermocouples (T/Cs), Resistance Temperature Detectors (RTDs), milliamps, millivolts, and volts dc. The equivalent PV signal is compared with the limit setpoint and any error (difference) de-energizes a limit output relay.

  • Page 61: Table 5-5 Change A Setpoint Value Procedure

    The latching relay cannot be reset until the PV input signal drops below latching relay the high limit setpoint or rises above the low limit setpoint. Press the [RESET] key or make contact closure of an external switch if the digital input option is present. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 62: How To Monitor Your Limit Controller

    How to Monitor Your Limit Controller Diagnostic error The UDC3300 performs background tests to verify data and memory messages integrity. If there is a malfunction, an error message will be displayed. In the case of more than one simultaneous malfunctions, only the one with the highest priority will appear on the lower display.
  • Page 63 When a Limit Controller (non-FM models only) goes into “slave” mode, the LED indicator for RSP goes “ON” indicating “SLAVE” mode. Also, keys do not work. You cannot make any adjustments to the configurable parameters. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 64: Alarm Setpoints

    A2S1 VAL = (Alarm 2, Setpoint 1 value) A2S2 VAL = (Alarm 2, Setpoint 2 value) to change any alarm setpoint value you select in the upper display. Return to normal LOWER operation DISPLAY UDC3300 Limit Controller Product Manual 1/01...

  • Page 65: Restarting After Power Loss

    Refer to the Configuration section under Set Up prompt “LIMIT” and make your selection at Function prompt “POWER UP.” 1/01 UDC3300 Limit Controller Product Manual...
  • Page 66 UDC3300 Limit Controller Product Manual 1/01...

  • Page 67: Section 6 - Input Calibration

    Introduction This section describes the field calibration procedures for Input 1. Every UDC3300 Limit 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.

  • Page 68: Minimum And Maximum Range Values

    0.00 mV 50.00 mV Volts 1 to 5 Volts* 1.00 Volts 5.00 Volts 0 to 5 Volts* 0.00 Volts 5.00 Volts 0 to 10 Volts* 0.00 Volts 10.00 Volts * not available for FM models UDC3300 Limit Controller Product Manual 1/01...

  • Page 69: Preliminary Information

    Tag and disconnect any field wiring connected to the input terminals on wiring the rear of the controller. Figure 6-1 shows the wiring terminal designations for Input #1. Figure 6-1 Input #1 Wiring Terminals L2/N Input 1 connections – 22648 Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 70: Table 6-2 Equipment Needed

    • Two insulated copper leads for connecting the calibrator to the controller. • Place current source at zero before switching ON. • Do not switch current sources OFF/ON while connected to the UDC3300 input. UDC3300 Limit Controller Product Manual 1/01...

  • Page 71: Input #1 Set Up Wiring

    Connect a cold junction resistor to terminals 25 and 27 for Input #1. See Figure 6-2. Figure 6-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath L2/N – T/C Extension Wire C/J Resistor Millivolt Source – Copper Leads Ice Bath 24205 Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 72: Figure 6-3 Wiring Connections For Thermocouple Inputs Using A Precision Resistor

    Precision 500 Ohm Resistor Copper Leads – Millivolt Source Caution: The accuracy of the controller is directly affected by the accuracy of this resistor. At a minimum, use a 0.1%, 25ppm resistor. 22628 Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 73: Figure 6-4 Wiring Connections For Rtd (Resistance Thermometer Device)

    Use the copper leads and connect the calibrator to the rear terminals of Input #1. See Figure 6-4. Figure 6-4 Wiring Connections for RTD (Resistance Thermometer Device) L2/N – Decade Resistance Copper Leads equal length 22629 Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 74: Figure 6-5 Wiring Connections For Radiamatic, Millivolts, Or Volts (Except 0 To 10 Volts)

    Input #1. See Figure 6-5. 10 volts) inputs Figure 6-5 Wiring Connections for Radiamatic, Millivolts, or Volts (except 0 to 10 Volts) L2/N – – Millivolt/Volt Source 22630 Copper Leads Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 75: Figure 6-6 Wiring Connections For 0 To 10 Volt Inputs

    Use the copper leads and connect the calibrator to the rear terminals of Input #1. See Figure 6-6. Figure 6-6 Wiring Connections for 0 to 10 Volt Inputs L2/N 100K 100K – 0 to 10 Volt Source Copper Leads 22631 Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 76: Figure 6-7 Wiring Connections For 4 To 20 Ma Inputs

    Use the copper leads and connect the calibrator to the rear terminals of Input #1. See Figure 6-7. Figure 6-7 Wiring Connections for 4 to 20 mA Inputs L2/N 250Ω resistor assy – Copper Leads – 4 to 20 mA Source 22632 UDC3300 Limit Controller Product Manual 1/01...

  • Page 77: Input #1 Calibration Procedure

    Adjust your calibration device to an output signal equal to the 0% range value for your particular input sensor. See Table 6-1 for Voltage or Resistance equivalents. Wait 15 seconds, then go to the next step. Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 78: Table 6-5 Input #1 Calibration Procedure

    ATTENTION When calibrating T/C inputs using a precision resistor, calibrate the cold junction as 77°F(25°C). Exit the Calibration Mode The controller will store the calibration constants and exit calibration mode. FUNCTION UDC3300 Limit Controller Product Manual 1/01...

  • Page 79: Section 7 - Troubleshooting / Service

    The following topics are covered in this section. section? Topic See Page Overview Troubleshooting Aids Power-up Tests Status Tests Background Tests Controller Failure Symptoms Troubleshooting Procedures Parts Replacement Procedures Maintenance (Cleaning) Continued on next page 1/01 UDC3300 Limit Controller Product Manual...
  • Page 80 Overview, Continued Installation related Read the Installation section in this manual to make sure the UDC3300 problems 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.

  • Page 81: Troubleshooting Aids

    Two consecutive failures of Background Input 1 integration INP1 RNG Input 1 Out of Range Background PV LIMIT PV Out of Range Background RAM TEST RAM test failed Power-up or Status Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 82: Table 7-2 Procedure For Identifying The Software Version

    Upper Display Software version Lower Display Number VERSION Please give this number to the Customer Support person. It will indicate which version of UDC3300 you have and help them determine a solution to your problem. UDC3300 Limit Controller Product Manual 1/01...

  • Page 83: Power-Up Tests

    Power-up Tests What happens at When the controller is powered-up, three tests are run by the UDC3300 power-up software to ensure memory integrity. As the tests are run, the displays will appear as shown in Table 7-3. Table 7-3 Power-up Tests...

  • Page 84: Status Tests

    RAM TEST CONF TEST CAL TEST FACT CRC Identify the problem and correct the failure as shown in Table 7-5. Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 85: Table 7-5 Status Tests

    2. Check the calibration. Make sure 0 and the change in input type. 100% are correct values. 3. Recalibrate if step 1 is unsatisfactory. Refer to Section 6 - Input Calibration. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 86: Background Tests

    Background Tests Introduction The UDC3300 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.

  • Page 87: Table 7-6 Background Tests

    PV out of range. 1. Make sure the input signal is correct. PV = INP1 + INP1 BIAS 2. Make sure the Bias setting is correct 3. Recheck the calibration. Use Bias of 0.0. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 88: Controller Failure Symptoms

    This may lead to a different troubleshooting procedure. If the symptom still persists, refer to the installation section in this manual to ensure proper installation and proper use of the controller in your system. UDC3300 Limit Controller Product Manual 1/01...

  • Page 89: Troubleshooting Procedures

    Check the system for Brown-outs, Refer to Section 2 - Installation. heavy load switching, etc., and conformance to installation instructions. Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 90: Table 7-9 Troubleshooting Latching Output Relay Failure

    ALM1 or ALM2 is lit. Check the field wiring. Make sure the NO or NC contact wiring is correct on the alarm output terminals. Refer to Section 2 – Installation for details. Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 91: Table 7-11 Troubleshooting A Keyboard Failure

    Press each key. If it works, the key name will appear in the lower display. Replace the display/keyboard if any Refer to “Replacement Procedures” in keys are shorted out. this section. Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 92: Table 7-12 Troubleshooting A Communications Failure

    Press [FUNCTION] until you see: Upper Display DISABL Lower Display LOOPBACK Press s or t, you will see: Upper Display ENABLE Lower Display LOOPBACK The test will run until the operator disables it here. UDC3300 Limit Controller Product Manual 1/01...

  • Page 93: Parts Replacement Procedures

    • DMCS Communications • RS422/485 Communications Equipment needed To accomplish the procedures that follow, you will need the following equipment: • Phillips Head Screwdriver • Flat Bladed Screwdriver • Small Pliers Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 94: Figure 7-1 Chassis Removal

    Grasp the bezel and pull the chassis out of the case. Figure 7-1 Chassis Removal Insert screwdriver and pry forward Grasp bezel and pull chassis out Loosen screw 22637 Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 95: Figure 7-2 Display/Keyboard Replacement

    Reinstall chassis into case. Press in hard, then tighten the screw. Figure 7-2 Display/Keyboard Replacement Display keyboard Pull printed release points wiring boards out slightly Printed wiring boards release points Display/keyboard Chassis assembly Rubber bezel and window 22638 Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 96: Figure 7-3 Removing The Printed Wiring Boards

    Pull both boards out of the chassis assembly. Figure 7-3 Removing the Printed Wiring Boards Pull printed wiring boards out of chassis Printed wiring boards release points Chassis assembly Rubber bezel and window 22639 Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 97: Figure 7-4 Printed Wiring Board Identification

    MCU/Output Boards Note: the transformer connectors are polarized and will only go on one way 2-Pin Transformer connections are interchangeable. Either may be used on Digital Input Board. 22649 Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 98: Table 7-16 Power Input Board Replacement Procedure

    Reinstall the chassis into the case. Push in hard, then tighten screw. Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 99: Table 7-17 Digital Input Board Replacement Procedure

    Reinstall the chassis into the case. Push in hard, then tighten the screw. Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 100: Table 7-18 Communications Board Replacement Procedure

    Reinstall the chassis into the case. Push in hard, then tighten the screw. Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 101: Table 7-19 Mcu/Output Board Replacement Procedure

    Reinstall the chassis into the case. Push in hard, then tighten the screw. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 102: Maintenance

    Maintenance Cleaning If you find it necessary to clean the elastomer bezel, use a 50% alcohol solution or mild soapy water. UDC3300 Limit Controller Product Manual 1/01...

  • Page 103: Section 8 - Parts List

    Exploded View Introduction Figure 8-1 is an exploded view of the UDC3300 Limit Controller. Each part is labeled with a key number. The part numbers are listed by key number in Table 8-1. There is a list of parts not shown in Table 8-2.

  • Page 104: Parts Not Shown

    30756764-002 Rear Cover Kit 30755223-002 DIN Adapter Kit, Blue 30755223-003 DIN Adapter Kit, Gray 30757088-501 Cold Junction Resistor 30756683-001 NEMA 3 Gasket (panel to case) 30757215-001 NEMA 4 Front Face Kit 30757069-001 Bezel Cover UDC3300 Limit Controller Product Manual 1/01...

  • Page 105: Section 9 - Appendix A How To Apply Digital Instrumentation In Severe Electrical Noise Environments

    What’s in this section This section contains the following information: Topic See Page Overview Potential Noise Sources Prevention Methods Recommended Wiring Practices Power Source Considerations Noise Suppression at the Source 1/01 UDC3300 Limit Controller Product Manual...

  • Page 106: Potential Noise Sources

    These include: • Large relays • Contactors • Motor starters • Business and industrial machines • Power tools • HID (high intensity discharge) lights • Silicon controlled rectifiers (SCRs) that are phase-angled fired. UDC3300 Limit Controller Product Manual 1/01...

  • Page 107: Prevention Methods

    Therefore, “suppression” is usually a last resort for those extreme situations where the other methods are insufficient by themselves. See Noise Suppression at Source which follows. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 108: Recommended Wiring Practices

    Line Power Earth Ground Line Voltage Digital I/O ANALOG I/O Process Variable Thermocouple dc Millivolts Low level (<100V) 4-20 mA dc 1-5 Vdc DIGITAL I/O Low Voltage (<100V) Computer Interface Continued on next page UDC3300 Limit Controller Product Manual 1/01...
  • Page 109 Attach it firmly to a proven good earth ground such as a metal stake driven into the ground. • All shields should be grounded at one end only — preferably the instrument end. 1/01 UDC3300 Limit Controller Product Manual...

  • Page 110: Power Source Considerations

    Figure 9-1 is an illustration of a separate transformer required to supply equipment power to digital equipment. Figure 9-1 Transformer for Digital Equipment Power source To digital 120/240 Vac electronic single phase equipment 20779 UDC3300 Limit Controller Product Manual 1/01...

  • Page 111: Noise Suppression At The Source

    Table 9-2 lists part numbers for recommended MOV devices. Table 9-2 MOV Devices Part Number 30732481-001 30732481-002 Maximum AC 130V 275V Energy Pulse Rating 10 Joules 15 Joules Supplier (General Electric) V130LA10A V275LA15A Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 112: Figure 9-2 Transient Suppression In Inductive Coils

    (see Table 9-3). Table 9-3 Coil Voltage vs Resistor Voltage Rating Coil Voltage Resistor Voltage Rating 115V 1/4 Watt 230V 1 Watt 460V 3 Watt 550V 5 Watt Continued on next page UDC3300 Limit Controller Product Manual 1/01...

  • Page 113: Figure 9-3 Contact Noise Suppression

    An RC network (47 ohms and 0.1 microfarad) is available as part number 30371852-001. Similar RC networks are available from Electrocube Inc. (part number RG1782-3) and from Industrial Condensor Corporation. Continued on next page 1/01 UDC3300 Limit Controller Product Manual...

  • Page 114: Figure 9-4 Dc Load Noise Suppression

    (see Figure 9-4). The value of R should be less than or equal to the DC resistance of the inductive load. Figure 9-4 is an illustration of DC load noise suppression. Figure 9-4 DC Load Noise Suppression D.C. supply – Inductive load Diode 20782 UDC3300 Limit Controller Product Manual 1/01...
  • Page 115 Index Alarm circuit wiring 11 DC Load Noise Suppression 104 Alarm relay 1 Decimal point location 36 Alarm Relay Output failure 80 Diagnostic error messages 52 Alarm Setpoints 54 Digital Input Board Replacement Procedure 89 Alarms Set Up Group 30, 42 Digital input connections 16 Application related problems 70 Dimensions 8...
  • Page 116 Prompt hierarchy 20 Lockout Set Up Group 25 Protective bonding 10 Loopback 41 Low limit control 35 Recommended Wiring Practices 98 Reset of relay 1 Response-delay timer 41 RS422 communications 53 RS422/485 Communications Board 90 UDC3300 Limit Controller Product Manual 1/01...
  • Page 117 Index Security code 34, 48 Setpoint high limit 35 Setpoint low limit 35 Shed time 40 Shock hazard warning 57, 69, 79 Signal and power line separation 97 Software version 72 Status Group 31 Status Tests 74 Suppression at the source 97 Surge suppressors 101 T, U, V Temperature units 36...

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