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UDC5300 Controller User Manual, 51-52-25-58

1. TB 4 25 TB 4 CONN 2 26 L1 27 L2 N E TT J 29 DO1C 30 DO1 NC 31 DO2 C D 32 DO2 NO 32 Figure 4 5 Slot 4 Terminal Connections UDC5300 Controller User Manual Wiring 4 9 Wiring Analog input signal connections 4 10 See the specifications in Section 2 for acceptable voltage and current signal inputs Connect current and voltage inputs to the appropriate terminals See Figure 4 6 for input connection methods ATTENTION Any analog channel left unused after wiring the instrument for its intended application should be shorted Do not leave unused analog inputs unwired and open If for example the controller s analog input 3 AI3 will not be used connect a wire between terminals 15 and 16 see Figure 4 3 CAUTION Safety isolation exceeding the safe working level of 30 V RMS 42 4V peak is not provided between analog inputs If the working voltage of any analog input exceeds this level use suitable wire gauge and insulation on all analog inputs and use proper safety precautions when handling all analog input wiring ATTENTION When the incoming field signal is current instead of voltage a 250 ohm resistor with 0 1 tolerance is used as a Current shunt mounted on the input terminals as shown in Figure 4 8 Use p n 074477 for 4 mA to 20 mA input conve
2. STORAGE gt STORAGE gt DS STAT m gt BT CTRL gt BT NUMBER y DS SETUP DSWARN lt BT SETUP lt DS INIT y DS FILES gt FMT MCRD PRETUNE REVIEW PROGRAM MODE MENU READ ONLY gt LP1 gt LP2 gt SET MODE ONLINE Figure 6 2 Online Mode Menus 6 4 UDC5300 Controller User Manual 5 00 Modes Menus Prompts and Keypad Basics Program mode prompts 5 00 Figure 6 3 shows the prompts in Program mode Program mode is used to configure every type of function block except the system block and to perform setup functions such as setting the clock and programming security passwords Note that when a function block is selected for edit the subsequent prompts are the names of input and internal parameters for which values must be specified if the factory defaults are not appropriate The basic idea is that you work your way through the parameters in the order they are displayed to program the function block This sequence is recommended because the value specified for a parameter early in the sequence of prompts for a particular block type can affect what subsequent parameters are selected A parameter s value may also affect what are valid values fo
3. INC Analog Input 1 ON Relay 1 PID PV Loop 1 0 100 EA DEC Relay 2 Position Proportioning Analog Input 2 Slidewire Feedback Analog S R LG Output 1 1 V Power for Slidewire Feedback INC Analog Input 3 X Relay 3 PID PV Loop 2 0 100 DEC Relay 4 DIAT Configuration 26 226 Two Independent PID Loops One with Position Proportioning Relays Out and One with Direction Impulse Adjusting Relays Out Figure 5 3 Two Loop Factory Configurations continued 5 34 UDC5300 Controller User Manual 5 00 Analog Input 1 Planning Relay 1 Relay 2 DEO PID y Loop 1 0 100 Analog Input 2 V Aki PID Loop 2 0 100 Ae DIAT Relay 3 me DEO Relay 4 DIAT Configuration 27 227 Two Independent PID Loops Each with Direction Impulse Adjusting Relays Out Analog Input 1 PV 0 100 Analog Input 2 PV PID C Loop 1 Relay 1 0 100 PID C Loop 2 Relay 2 Configuration 28 228 Two Independent Loops Each with ON OFF Relay Figure 5 3 Two Loo p Factory Configurations continued 5 00 UDC5300 Controller User Manual 5 35 Planning 5 5 Tasks That Precede Programming Introduction Regardless of whether you decide to do freeform programming or to start with one of the factory configurations there are a few other things to be considered before programming the c
4. Slot 2 If model selection If model selection from Table Ill is 1_ from Table Ill is 3 One Analog Input Three Analog Inputs TB 2 2 TB 2 9 DU TB 2 CONN VO TB 2 CONN JO el me DO meme IT 11 All B 11 Ali B M 12 DU 12 Al2 A VG 13 r ne 13 Al2 C ot YO 14 Used YO 14 Al2B YO 15 15 Al3 ST 16 DO 16 Al3 16 16 Figure 4 3 Slot 2 Terminal Connections 5 00 UDC5300 Controller User Manual 4 7 Wiring Slot 3 If model selection from Table Ill is _C Three Discrete Inputs and One Current Output or _V Three Discrete Inputs and One Voltage Output If model selection from Table Ill is _D Two Discrete Inputs and Two Output Relays 17 TB 2 17 TB 3 D TB 3 CONN OC TB 3 CONN D 17 AO2 A O 17 DO3 NO O 18 AO2 A O 18 DO38C 19 DI1 19 DO3NC OC a DB OC 21 Doso QC 22 DI2 C O 22 DI1 23 DI3 23 DI1 2C OC act sae OC lt a 24 24 Note If Table III selection is 0 TB3 is not used Figure 4 4 Slot 3 Terminal Connections 48 0000 UDC5300 Controller User Manul 0 5 00 5 00 Slot 4 All models Power and Two Output Relays
5. S S S S S S OJo AOKOKA olele 7 16 UDC5300 Controller User Manual DIN DO1 SE AIS mei ohm dropping resistor for 1 to 5 volt input Programming diagram Al1 TYPE LINEAR Al3 TYPE LINEAR DI 5 00 Using a Factory Configuration LP1 PV Al1 OV LP1 TYPE AO1 INP LP1 OV AO1 TYPE ADV CAT LP1 OTRK AI3 OV LP1 FB AO1 BC LP1 RMAN DI1 OS DO1 INP DI1 OS C DO1 UDC5300 Controller User Manual 7 17 Using a Factory Configuration 7 4 7 Configuration 07 107 PID with Time Proportioned Relay Output Description This PID strategy uses a DAT Duration Adjusting Type analog output AO function block to interface between the loop LP block and the discrete output DO block associated with the relay In this application the AO block is not associated with analog output terminals Basic diagram Analog Input 1 PV 0 100 Wiring diagram PID Alt DO1 QIO CIC OOO CH S S S S S S S olloa DRITA 7 18 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Programming diagram AO3 TYPE DAT Ali TYPE LP1 PV Al1 OV LP1 TYPE AO3 INP LP1 OV AO3 OUT
6. o f W Jumpers W2 amp W3 Figure 18 2 Location Of Termination Jumpers W2 And W3 5 00 UDC5300 Controller User Manual 18 5 Setting Up for Serial Communications 18 6 UDC5300 Controller User Manual 5 00 Using Maintenance Mode 19 Using Maintenance Mode 19 1 Introduction Overview Maintenance mode functions are available for e calibrating analog inputs and outputs e running diagnostics e clearing configuration and calibration e resetting the unit e specifying the frequency of the AC power at the site e performing full or partial upgrade of optional features e displaying firmware version information e specifying the power off period that will trigger a cold start ATTENTION Maintenance mode is an offline mode All outputs will be frozen while in Maintenance mode and data storage will stop until the controller is returned to Online mode ATTENTION All prompts and selections in this section are listed as shown when the controller s language is set to English Other languages are available as described in Section 9 What s in this section 5 00 The following topics are covered in this section Topic Page 19 2 Calibrating Analog Inputs 19 2 19 3 Calibrating Analog Outputs 19 5 19 4 Running Diagnostics 19 7 19 5 Database Services Clearing Configuration and 19 7 Calibration and Upgrading Optional Features 19 6 Resetting the Unit 19 7 19 7 Spec
7. 1 20 18 201 80 403 60 605 40 1210 80 2 14 01 140 14 280 28 420 42 840 83 3 10 65 106 51 213 01 319 52 639 03 4 8 41 84 08 168 17 252 25 504 50 5 7 29 72 87 145 74 218 62 437 23 6 6 16 61 63 123 26 184 89 369 78 5 00 UDC5300 Controller User Manual 17 9 Storing Data 17 3 Data Storage Operation Introduction Here are some typical Data Storage operating tasks e Initializing a card e Starting and stopping storage 3 methods e Start stop all storage via STORAGE ENABLE DISABLE menu e Start stop all storage via external enable discrete e Start stop storage batches via BT CTRL menu or via remote discrete e Checking status with DS STATS menu or BT NUMBER e Checking contents of the card e Reading data storage messages These tasks are described below Initializing a card When replacing a card with a newly formatted or preused card it is not necessary to reenter the schedule to continue data storage Instead select the online STORAGE menu select DS INIT then select INITTYPE CURRENT The current schedule will be established on the new card buffered data will be stored to the card and if in batch mode the batch counter will be reset to zero O Any data previously on the card is deleted during initialization To initialize a card using a new storage setup see 16 2 Initialization activates storage and allocates a file for each da
8. Analog Input 1 N PID V Loop 1 0 100 Analog Input 2 IN y PID Loop 2 0 100 C Relay 2 Time Prop Configuration 22 222 Two Independent PID Loops Each with Time Proportioned Relay Out 0 100 Analog Input 1 PV on Relay 1 0 100 Time Prop INC Analog Input 3 D Relay 3 PID PV Loop 2 0 100 DEC Relay 4 Position Proportioning Analog Input 2 Slidewire anne Feedback Analog Output 1 1 V Power for Slidewire Feedback Configuration 23 223 Two Independent PID Loops One with Time Proportioned Relay Out and One with Position Proportioning Relays Out 5 00 Figure 5 3 Two Loop Factory Configurations continued UDC5300 Controller User Manual 5 33 Planning Analog Input 1 x PV te C Relay 1 0 100 VA Time Prop INC Analog Input 2 N Relay 3 PID PV Loop 2 0 100 DEC Relay 4 DIAT Configuration 24 224 Two Independent PID Loops One with Time Proportioned Relay Out and One with Direction Impulse Adjusting Relays Out PV 0 100 Output 3 INC Relay 1 Analog Input 1 PID Hee i o Loop 1 DEC 0 100 Relay 2 Position a 4 Analog Input 2 Proportioning Slidewire Feedback Analog 0 100 Output 1 1 V Power for Analog Input 3 Slidewire Feedback Configuration 25 225 Cascade PID with Position Proportioning Relays Out
9. For this operator Definition if this is true then Result is AND If all programmed inputs are ON All programmed inputs are ON 1 Result is ON ON 1 OR If at least 1 programmed input is ON At least 1 programmed ON 1 Result is ON input is ON 1 XOR Uses Inputs A and B only Input A is ON 1 and Input ON 1 B is OFF 0 If one and only one input is ON Result Input A is OFF 0 and Input ON 1 is ON B is ON 1 RESET SET FF Rising edge of Input A turns Result Inout A is ON 1 ON 1 ON Reset Set Flip Flop Rising edge of Input B resets Result Input A is OFF 0 and Input OFF 0 B is ON 1 Input A Input B TOGGLE FF Toggle Flip Flop Rising edge of Input Input A changes from ON 1 if it was A inverts Result OFF 0 to ON 1 rising OFF 0 or OFF 0 edge if it was ON 1 Input A changes from unchanged ON 1 to OFF 0 falling Reset Set FF Input A ui I Toggle Flip Flop ONE SHOT Rising edge of Input A turns Result Input A is ON 1 for any ON 1 for 1 scan ON for one machine scan cycle length of time cycle of the instrument then OFF 0 Input A HU n Result One Shot PASS Passes Input A s state unchanged to Input A changes state same as Input A CONDITION TYPE 9 50 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 7 5 CV Totalizer TOTL Introduction This function totali
10. Parameter setpoint 21 8 UDC5300 Controller User Manual 5 00 Messages Requires Input Parameter Requires a Deviation Parameter Deviation alarm does not contain deviation Program alarm with deviation Trend Has Too Many Points For Rate Selected Data Storage cannot store more than 3 points at 1 4 second scan rate Change number of points to be compatible with scan rate A function block type was loaded that does not exist For example you loaded a Profile but the unit does not have the Profile option Re program or re load correctly Type Incompatible With Hardware Analog output type is different from hardware setting For example analog output is programmed as CAT but hardware is set to VAT Change programming to be compatible with hardware or vice versa then reload configuration or reconfigure the block Type Requires Hardware Hardware is missing for the programmed analog output or discrete output relay Either ignore the message Knowing that those particular points did not get loaded or verify configuration and make sure that the points that are in the configuration match the hardware components Undefined Function Block Request Value Written to Indirected Point An input has been connected and user has tried to write a value to that input For example if a control loop setpoint is connected to Al1 OV you will receive this message if you try t
11. Supply Voltage AKAOA 32 Time Proportioning DAT Figure 4 10 DAT Typical Wiring 4 14 UDC5300 Controller User Mnual 0 5 00 Wiring Communications 5 00 The communications network is based on a Honeywell protocol with a Master Slave relationship Alternatively Modbus may be used This network is configured around the IEEE RS 422 485 multi drop standard The Master is a PC host running any software compatible with Honeywell protocol A slave can be any instrument equipped with serial communications capability All communication equipment supporting the 422 485 differential drive must be correctly installed and properly terminated to ensure a reliable network Instructions for terminating the last controller on the data link are provided in Section 18 Table 4 2 shows the five connections per device Table 4 2 Communications Connections Connection Meaning TX The positive signal of the transmitter TX The negative signal of the transmitter SHield The shield of the communications cable RX The positive signal of the receiver RX The negative signal of the receiver ground TB4 Terminal 25 and earth ground for the communication connections TB1 Terminal 8 This wire will connect all of the suppression circuitry on the receive and transmit lines to the earth ground A triple shielded cable with a shield around each of the twisted pair
12. gt PRGLP gt PRG AO PRGAL lt PRGCV lt PRGDO lt PRG Di y PRG CN gt PRG SPP gt COPY BLK gt PRG DPYS y SET CLK lt SER COMM lt SECURITY lt FEATURES y CFG FILE gt FACT CFG gt SCAN FRQ gt LANGUAGE gt MAINT gt SET MODE MAINT gt CALIBAI gt CALIBAO gt RUN DIAG y PROD ID lt MAIN FRQ lt RSTUNIT lt DB SRVCS v WS TIME Figure 6 1 Top Level Menu Choices 5 00 UDC5300 Controller User Manual 6 3 Modes Menus Prompts and Keypad Basics Online mode submenus Figure 6 2 shows the functions in the Online mode menu submenus These are presented here to give you a general idea of what you can do in Online mode Use of these menus is described in Section 15 ON LINE TUNE LP m LP1 gt LP2 PROFILE gt PRF EDIT gt PRFSTOR gt PRF LOAD SUMMARY ALRM SUM DIAG SUM gt ANLG SUM gt DISC SUM y PRODID lt TIME lt DEL DIAG DAT ENT gt DE ALARM gt DE CN gt DE FORCE gt DE AIADJ Y SET AO
13. gt TEST KEYPAD TEST RAM SIZE Y TEST FACTORY lt TEST MEM CARD DBSRVCE gt CLRCFG gt CLRCAL gt CLRALL gt FULL UPG l INCR UPG gt RST UNIT gt MAIN FRQ gt PROD ID gt WS TIME gt SET MODE MAINT Figure 6 4 Maintenance Mode Prompts 5 00 UDC5300 Controller User Manual 6 7 Modes Menus Prompts and Keypad Basics 6 3 User Interface Overview This subsection explains the theory of key and menu use An example of how to use the keys to select a parameter value is in 6 5 6 3 1 Introduction Use keypad for everything All programming operator and maintenance functions are accomplished using the keypad on the front of the controller see Figure 6 5 A summary of key functions is provided in Table 6 3 SP MANUAL DISPLAY AUTO SETPOINT PRGM Figure 6 5 UDC5300 Viewing and selecting menu items with the INCREMENT A DECREMENT VW and ENTER keys Items from the top level of the Program mode Online mode or Maintenance mode menu are displayed on the bottom line of the screen Use the INCREMENT A and DECREMENT Y keys to cycle through a menu When the function to be used or item to be configured is displayed press the ENTER key to select it The INCREMENT A and
14. 19 9 Specifying the Power Off Period for Warm Start Introduction The behavior of the controller when recovering from a short term power failure is different than that following a long term power failure After a short power failure the controller will resume Operations using process values retained from before the power failure This is referred to as a warm start However after a longer power failure all buffers storage and display are cleared accumulated values of interval timers and totalizers are reset to initial values the loop auto manual and setpointl setpoint2 statuses are retained and the loop output is set to zero 0 unless configured to use a Failsafe value for the analog output You must specify the length of time that is the maximum for which the process can safely resume at pre power loss conditions The Maintenance menu contains the item WS TIME for this purpose e Any interruption of power less than or equal to this time will result in a warm start when power is restored e Any interruption of power greater than this time will result in a cold start when power is restored Choices 19 8 The warm start time choices are e NONE Always executes cold start e Minutes through 5 10 15 20 30 60 90 e Seconds 5 10 20 30 UDC5300 Controller User Manual 5 00 Changing the CAT VAT Switch Settings 20 Changing the CAT VAT Switch Settings 20 1 Introduction Overview
15. A3 Output High Limit NUMBER A3 Output Lower Limit and A3 Output High Limit Specify the scaled range for A3 Range Lower Limit RNGH Range High Limit NUMBER Range Lower Limit and Range High Limit Enter the outputs range when displayed as a trend with Honeywell SDA software The output is not clamped nor does it flash when the output value is outside the range 5 00 UDC5300 Controller User Manual 9 63 Using Program Mode to Configure Function Blocks and Features 9 7 11 CV Compare CMPARE This operation compares the values of two inputs using the operator selected during configuration The output of the block CVn OS is ON 1 if the input comparison is true Compare can be used instead of an Alarm s output to control a relay It can also provide ON OFF control with hysteresis If hysteresis is given a value then CVn OS will not go OFF 0 until hysteresis value is exceeded See Figure 9 4 and Figure 9 5 Result is then processed according to the specified condition type and condition time CV compare prompts Table 9 30 describes the Compare prompts Table 9 30 CV Compare Prompts Input Decimal Position XX XXXX XXX XXX XXXX XX XXXXX X XXXXXX Input Decimal Position Move the decimal point to the position used by the inputs to the CV block Input 1 Source INP2 Input 2 Source Operator NUMBER PARM analog GTE Input 1 Source and Input 2 Source
16. AH alarm high AL alarm low DF diagnostic failure DG diagnostic general SF storage full SW storage warning AX analog safe parameter DX discrete safe parameter O OoO000000 UDC5300 Controller User Manual 5 00 Planning 5 2 5 Summary of Outputs Available Introduction Table 5 3 provides a complete listing of all output parameters that can serve as inputs to other function blocks Table 5 3 Function Block Output Designators Function Function Block Output Output Name Output Block Name Code Type Code Al Analog Input OV Output Value analog AO Analog Output OV Output Value analog BC Back Calculation Value Feedback analog DI Discrete Input OS Output State discrete DO Discrete Output OS Output State discrete LP Control Loop OV Output Value analog PV Process Variable analog DV Deviation Value analog WS Working Setpoint analog S1 Setpoint 1 Value analog S2 Setpoint 2 Value analog BC Back Calculation Value Cascade feedback analog AM Auto Manual Status discrete SS Setpoint 1 Setpoint 2 Status discrete OS Output Status ON OFF loop only discrete AL Alarm PV Process Variable alarm s input analog OS Output Status discrete CN Constant OV Output Value analog PV Process Variable Constant s input analog 5 00 UDC5300 Controller User Manual
17. INP2 0 The output of any CV block can be displayed on a PVCV type OPER ADD Ensure that Setpoint 1 is viewable As described in Section 9 you can configure which online displays are included in the cycle of primary displays accessed with the DISPLAY key Be aware that specifying PVSPL1 during display programming selects a display that shows the working setpoint If the working setpoint is clamped at the LP1 SPHL based on the anti sooting factor this working setpoint will not be the same as Setpoint If you want to also be able to view and change Setpoint 1 then also select PVS1L1 to be included in the display cycle 5 00 UDC5300 Controller User Manual 12 13 Carbon Potential Option 12 4 3 Display Configuration Introduction Our example uses primary displays to enable the operator to view and change values in the carbon potential strategy Table 12 16 shows the selections recommended Add or remove displays to satisfy your particular operational requirements Instructions for selecting the displays to be included in the online display cycle are provided in 9 11 Table 12 16 Displays Used by Carbon Potential Example PRG DPYS Prompt Selection Purpose PRG DPY1 PVSPL1 display PV and display change working SP of loop 1 PRG DPY2 PVOUL1 display PV and display change loop 1 output PRG DPY3 PVCVL1 display PV and CV1 probe temperature DPY3 CV 1 PRG DPY4 PVS1L1 display and display
18. gt PRGDPYS gt gt DPY1 gt DPY2 gt DPY3 gt DPY4 DPY10 gt FEATURES gt EXPINP gt VALADJ gt FORCE gt PRETUNE gt ALARMS Y CUST INP lt PYROMETRY lt REVIEW DATSTR lt CN gt SECURITY gt ENABLE gt MASTER gt SET MODE OPER gt A M SEL Y STORAGE lt REVIEW lt SET PARM SP1 SP2 gt SER COMM gt UNITADDR gt PROTOCOL gt BAUDRATE gt PARITY gt DLLKOUT gt SET CLK gt SET MON gt SETDAY gt SET YEAR gt SETHRS gt SETMIN Y SET FRMAT gt CNF FILE gt STORE CNF gt STORE CAL gt LOAD CNF gt LOAD CAL gt FACT CFG gt LOAD CFGnn gt SCAN FRQ gt LANGUAGE gt SET MODE PRGM Figure 6 3 Program Mode Prompts UDC5300 Controller User Manual 5 00 Modes Menus Prompts and Keypad Basics Maintenance mode functions Figure 6 4 lists the function prompts in Maintenance mode These are presented here to provide an overview of the uses of Maintenance mode Instructions for performing these functions are provided in Section 19 MAINTENANCE gt CALIBAL gt Alt gt Al2 ced Al3 gt CALIB AO gt AO1 LOW gt AO1 HIGH gt AO2 LOW gt AQ2 HIGH gt RUN DIAG gt TEST DISPLAY
19. Input Specify the source of the input to the AO function block NUMBER range is 0 1 to 999 9 units minute units of the AO s input source Increasing Slew Limit and Decreasing Slew Limit Limits the rate of increase or decrease of the analog output Value entered is in terms of the AO s input source not in terms of the output as defined by OVLL and OVHL Variable slew limits are available by programming a CN constant block s Destination with IS or DS See Programming Constants Section 9 9 NONE Failsafe Specify whether or not failsafe is active in case of thermocouple failure burnout and if so which direction An input is considered to have failed when the controller detects loss of continuity or when the input is more than 10 out of range None Failsafe disabled Up Output will go to full scale value in case of input failure upscale Down Output will go to low value in case of input failure downscale Value Select this to permit entry of a value using FSV see below Prompt Applies Full name To IDPT all output Input Decimal ee Position INP all output Input types ISLW CAT VAT Increasing Slew DAT Limit DSLW Decreasing Slew Limit FSAF CAT VAT Failsafe DAT DAT Impulse Time NUMBER range is 0 to 300 seconds Impulse Time Specify the cycle duration for On and Off time of the output For example a time of 150 seconds will cause th
20. PTA BAD ID VALUE Increase step size See Table 13 2 PTA DB ACCESS Unknown hardware problem Consult technical support PTA TASK FAIL Unknown hardware problem Consult technical support 5 00 UDC5300 Controller User Manual 13 5 Final Preparations for Bringing the Controller Online 13 3 Commissioning Hints Introduction When you put your controller online it will not operate unless you take into account certain features of its design This subsection to intended to make you aware of these features Five good scans needed before it will go online A safety attribute built into the controller function blocks is to assume at startup that input values to the blocks are bad until they are measured good This attribute causes the controller to execute up to five scans of the control strategy before going online Failure to process all good inputs will result in the main display showing flashing asterisks instead of values Impossible to verify configuration without inputs A common error made during commissioning a controller is to attempt to verify a configuration with the inputs to the controller disconnected This will typically result in the main display flashing asterisks There are many online diagnostic routines that identify faults after the controller has successfully been placed in service but upon power up the controller must first be able to verify all inputs to all function blocks are good be
21. TYPE CAS P P1 1234 a ae TYPE CAS S Al2 OV OIL THERMOCOUPLE 1 SP1 is desired reaction vessel temperature 2 SP2 is the remote setpoint input of LP2 Figure 8 12 Function Block Diagram of the Cascade Control Strategy Both control loops in this product may be programmed to operate using up to two user defined set point parameters designated by SPI and SP2 Should you implement a control loop using one or both setpoints That depends on what is necessary to meet the requirements of the specific application being dealt with When in the on line mode and viewing a control loop s dedicated on line display the active set point of the live control loop can be switched between SP1 or SP2 as described in Section 14 Note that while both set point parameters may be programmed to have straight numeric values only SP2 may be defined as a remote set point That is SP2 may be set up so that its value is determined by the output value of another function block such as a setpoint profile In the cascade control strategy demonstrated in Figure 8 12 SP2 s remote set point functionality is exploited by the LP2 secondary cascade loop When this control configuration is made operational LP2 s working set point SP2 will have a value determined by LPI OV In Figure 8 12 the process values of each loop are the output values of the AII and AI2 analog input function blocks AI1 will produce temperature measurements of the reaction cha
22. The input to a CN can be a fixed number or the CN can be programmed to read its input value from another block s analog output value Output While the CN has an output value parameter OV and an output to retransmit its input value PV the CN type is unique in that it contains internal parameters that can be programmed to write the CN input value to a destination in another block The list of valid destinations is available when the CN DEST prompt is displayed This destination programming provides addition flexibility because it provides the only way to use a variable as the value of some parameters such as a loop s proportional band or slew limits During configuration of the proportional band value for example the only valid entry is OFF or a number However if a number is specified during loop programming this number can be overwritten with a variable if you configure the CN DEST to be LPn PB Loop n s proportional band Diagram 5 12 Constant CN OV output value PV Same as input value IN input DEST writes to destination not readable by other blocks UDC5300 Controller User Manual 5 00 Planning 5 2 4 6 Discrete Input Block Use A DI DO card supporting two or three discrete inputs is a controller option Each hardware discrete input is associated with a DI function block This DI block makes the field signal available to the other function blocks in the cont
23. User Manual 5 00 Wiring diagram O1 Programming diagram All TYPE LINEAR Al3 TYPE LINEAR Al2 TYPE LINEAR 5 00 Using a Factory Configuration LP1 PV Al3 Al1 OV LP2 PV LP1 TYPE AO3 INP LP1 OV STD LP1 FB AO3 BC Actuator Voltage Alt DOS TE ala INC S YoSH DEC Sh St KE Or DA SITSI 41 OH L2 N N SQ SQ N LOAD DO 911491 SHS STENE ES Load CHa ERNE RS Supply SES TESTES INC Al2 DEC DO1 Al3 OV LP2 TYPE AO4 INP LP2 OV STD t LP2 FB AO4 BC AO3 TYPE DAT AO3 OUT DO1 AO4 SLWR Al2 OV AO4 TYPE PP AO4 PA PP AO4 INC DO3 AO4 DEC DO4 CN9IN AQO1 INP 20 CN9 OV AO1 TYPE VAT AO1 INLL 0 AQ1 INHL 100 AO1 OVLL 0 AO1 OVHL 5 UDC5300 Controller User Manual 7 49 Using a Factory Configuration 7 4 24 Configuration 24 224 Two Independent PID Loops One with Time Proportioned Relay Out and One with Direction Impulse Adjusting Relays Out Description Two independent PID loops are configured Loop 1 uses one relay to provide a time proportioned output Loop 2 uses two other relays to provide direction impulse adjusting output A DA
24. Wiring diagram Using a Factory Configuration L1 S Of i S S S Actuator SUNESEN L2 N Voltage S SH S oi SEES TEEN INC SAML UENS DEC S TSIS TN SRI ENS INC Al2 DEC Programming diagram AO2 TYPE AO2 INP CAT CV9 A1 v9 FB1 AO2 BC Ali TYPE LP1 PV LP1 TYPE CV9 INP CV9 TYPE DO LINEAR Al1 OV SPLIT LP1 OV SPLT_S AO3 INP A CV9 A2 4 CV9 FB2 DO2 POSES AO3 TYPE PP LP1 FB CV9 BC AO3 PA PP AO3 INC DO1 Al2 TYPE AO3 SLWR Al2 OV AQ3 DEC DO2 LINEAR CN9 IN AO1 INP 20 CNY OV AO1 TYPE VAT AO1 INLL 0 AQ1 INHL 100 AO1 OVLL 0 AQ1 OVHL 5 5 00 UDC5300 Controller User Manual 7 13 Using a Factory Configuration 7 4 5 Configuration 05 105 PID Ratio Control with Current Output Description This strategy keeps the controlled variable in ratio with the wild variable Both variables are supplied as linear analog inputs via analog input AI blocks The output is CAT current adjusting type Basic diagram Controlled Analog Input 1 Analog PV 0 100 PID paren Loop1 4 20mA Wild Analog Input 2 Ratio
25. ZCUT CV TOTL parameter 9 52 zero adjustment on analog input 15 12 zirconia oxygen probes 12 2 Index 8 UDC5300 Controller User Manual 5 00 Honeywell Sensing and Control Honeywell 11 West Spring Street Freeport IL 61032 51 52 25 58 0500 Printed in USA www honeywell com sensing
26. 13 6 One approach to diagnosing sources of the flashing asterisk display is to use the SUMMARY displays in the Online menu see Section 15 to view the outputs of the function blocks that have been configured If the controller analog input values appear to be within range check for proper signal levels on other function blocks Finally verify proper signal flow has been maintained throughout your configuration UDC5300 Controller User Manual 5 00 Using Primary Displays to View Process Values and Change Setpoints 14 Using Primary Displays to View Process Values and Change Setpoints 14 1 Introduction Overview Up to ten primary operator displays can be accessed in the configured sequence by pressing the DISPLAY button repeatedly Primary displays contain live process data such as setpoint process variable deviation loop mode Automatic or Manual Setpoint Profiler status engineering units and alarm status as well as constants from CN blocks and calculated values from CV blocks This section describes the displays and their use Functions performed using the Online mode menu are described in Section 15 What s in this section The following topics are covered in this section Topic Page 14 2 Primary Display Description 14 2 14 3 How to Use Primary Displays 14 5 5 00 UDC5300 Controller User Manual 14 1 Using Primary Displays to View Process Values and Change Setpoints 14 2 P
27. 7 4 13 Configuration 13 113 Backup to Primary Controller or PLC Uses Position Proportioning Relays Out Description This strategy provides PID control as a backup to a primary controller or PLC One analog input is used for the PV another is used to provide the value from the primary to be used as the loop s output when Remote Manual is enabled via a discrete input Two relays are used for position proportioning output An analog output AO block with both its type and its positioning algorithm set to PP position proportioning interfaces between the loop LP block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO block is not associated with analog output terminals The analog feedback signal from the positioner s slidewire is received at AI2 The feedback is powered by a constant 1 V from the terminals associated with AOI and its VAT voltage adjusting type AO function block having an output range from 0 to 5 Because the input to the AO is 20 from a constant CN block a steady 1 V out is achieved 20 of the 5 V range A discrete input is used to trigger failover Its status turns on two relays in the UDC5300 one used to transfer line voltage from the primary controller s output circuits to the UDC5300 output circuits the other to transfer the feedback slidewire voltage from the primary controller to the UDCS5300 Control will be mainta
28. BEZEL OPEN The front bezel of the controller is open When the bezel is open data will be buffered in controller memory until the buffer capacity is exceeded Data is stored to the memory card only when the bezel is closed and latched MEM CARD Available space on the memory card has reached the programmed WARNING warning limit When active the SY1 SW system parameter output status will be high Logic 1 which may be used to trigger a discrete output MEM CARD FULL Memory card is full Data will continue to be buffered to the limit of the buffer capacity When active the SY1 SF system parameter output status will be high Logic 1 which may be used to trigger a discrete output INIT FAILED Initialization failed Possible reasons for failure are 1 The memory card was not formatted 2 The memory card is write protected 3 The memory card is defective MEMCARD MISSING Storage schedule is initialized and the memory card is missing Disappears when the proper card is inserted WRITE PROTECTED Storage schedule is active and the memory card is write protected Disappears when writing to the card is enabled The memory card battery is dead To avoid losing the card s data replace the battery while the card is still inside the controller UPDATING MEM Controller is flushing all buffered data to the memory card CARD CHECKING MEM The front panel has been opened and closed and the controller is checking CARD for a properly ins
29. Input 8 Example Input 1 minus Input 2 minus Input 8 Only standard deviation requires the use of all inputs e f the operator is absolute value or square root the block will calculate the absolute value or square root of Input 1 s value The other inputs are not used e f the operator is division the block will divide Input 1 by Input 2 The other inputs are not used e f the CV block is part of a loop output configuration the math operator cannot be ABSVAL SQRT or STDDEV Prompt Range Selections Full name OPER ADD Operator SUBT MULT DIV ABSVAL SQRT STDDEV FB OFF Feedback NUMBER PARM analog Feedback Specify the source of the feedback value used when this block is part of a control loop output configuration Select LPn BC or AOn BC to propagate the back calculation BC value from a downstream loop or AO Also program the upstream loop s feedback with this Math CV s back calculation value CVn BC You MUST program this CV s feedback to OFF if this CV is not used as part of a control loop output configuration Output Low Limit NUMBER OVHL Output High Limit Output Low Limit and Output High Limit Specify the output range Any computed output value that is outside the range will be clamped at the appropriate limit The clamped output value will flash when displayed 9 44 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Feat
30. MOLDING INSTRUMENT ae FRONT 10 KIT 19 sean SOFTWARE PLANE N PCA CLOCK 36 KIT s 20 or 21 DISPLAY FLAT i BATTERY FLEX CABLE 53 KIT 19 13 KIT 18 KIT 16 REFERENCE JUNCTION SENSOR AND CABLE 11 KIT 19 Figure 22 5 Exploded View of Instrument s Card Cage 5 00 UDC5300 Controller User Manual 22 11 Parts List 22 12 UDC5300 Controller User Manual 5 00 Cleaning the Front Panel Appendix A Cleaning the Front Panel Guidelines 5 00 The following are guidelines for cleaning the front panel of the controller when it has been properly installed in a panel as described in Section 3 and grounded as described in Section 4 e Clean the front panel with a damp cloth e If needed use a detergent containing no abrasives Do not use solvent cleaners e Always clean the front panel with the bezel closed UDC5300 Controller User Manual A 1 Cleaning the Front Panel A 2 UDC5300 Controller User Manual 5 00 Security Bypass Procedure Appendix B Security Bypass Procedure Overview Your controller has a security bypass code which allows you to enter secured areas of the product without using the master and or operator passwords described in Section 9 Bypass procedure The table below describes the security bypass procedure Security Bypass Procedure 783 3 To return to the previous menu without entering the secured area press the MENU button To enter the secured ar
31. O N01 RATIO DOT Al2 TYPE LP1 WILD i LP1 FB AO3 BC LINEAR Al2 OV 5 00 UDC5300 Controller User Manual 7 25 Using a Factory Configuration 7 4 11 Configuration 11 111 PID with Position Proportioning Relays Out Description This PID loop s output uses two position proportioning relays An analog output AO block with both its type and its positioning algorithm set to PP position proportioning interfaces between the loop LP block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO block is not associated with analog output terminals The analog feedback signal from the positioner s slidewire is received at AI2 The feedback is powered by a constant 1 V from the terminals associated with AOI and its VAT voltage adjusting type AO function block having an output range from 0 to 5 Because the input to the AO is 20 from a constant CN block a steady 1 V out is achieved 20 of the 5 V range Basic diagram INC Analog Input 1 Relay 1 PID PV SEE Loop 1 0 100 DEC Relay 2 Position Proportioning Analog Input 2 Slidewire Feedback 0 100 5 Output 1 1V Wiring diagram Alt ER aor TTS LOTS gt i S S S L1 Actuator H E HERS L2 N Voltage STN KE HS
32. PROCESSOR EXCEP Processor Exception CPU PROCESSOR RESET Processor Reset CPU TASK INIT FAIL Task Initialization Failure CPU QUEUEREADFAIL Queue Read Failure CPU RESPONSE FAIL Response Failure CPU REQUEST FAIL Request Failure CPU AED REPORT FAIL AED Report Failure CPU HANDSHAKE FAIL AED Handshake Failure CPU Al TASK OVERRUN Analog Input Task Overrun Al FBTASK OVERRUN Function Block Task Overrun CPU SLOT CARD FAIL Slot Card Failure Al CPU PS MEM STORAGE FAILURE Storage Failure MEM CPU DS STATUS LOST Data Storage Status Lost CPU RJ FAILURE Reference Junction Failure RJ Al CPU CLOCK FAILURE Clock Failure CPU CLOCKRESET Clock Reset CPU TIMING ERROR Timing Error CPU 21 4 UDC5300 Controller User Manual 5 00 Messages 21 3 Loop Error Indicators Introduction When a loop s PV SP2 or other parameter fails the loop switches to its default failsafe condition indicated by certain display symbols flashing To return the loop to its desired condition correct the failure Then if the loop s LBAD latching under LP SETUP is NO the loop will return to normal automatically If latching is YES also perform the action needed to return the loop to normal Table 21 3 Abnormal Loop Conditions and Indicators Desired Abnormal Default condition Flashing Action needed Condition Condition Failsafe
33. Planning 5 2 4 10 System Block Use The system SY block is the one block type not used to implement your control strategy It has no configurable inputs or internal parameters Its function is to monitor the activity of the controller and make this information available for display or reading by other blocks For example a DO can be programmed to open or close a relay when the memory card for the optional data storage feature is full Outputs 5 00 The reference junction temperature of a thermocouple is available as an analog output RT A number of discrete outputs are available to provide awareness of conditions AG An alarm state is active AH A high alarm condition is active AL A low alarm condition is active DG At least one diagnostic message present DF is not used at this time it is always OFF SF The removable memory card is full SW The available space on the removable memory card has reached the programmed warning limit See Section 17 for more information about data storage Note that the AX analog safe and DX discrete safe outputs are used by the controller s software to replace an unavailable function block output that another block is programmed to use AX and DX always have a value of OFF Use them only if you need to simulate connection to an OFF input UDC5300 Controller User Manual 5 19 Planning Diagram 5 20 System SY RT ref junction temp AG alarm global
34. STPT OFF Alarm Setpoint Specify the source of the alarm change the alarm setpoint when the unit is online CMPT OFF Compare Point For DEV LDEV and HDEV types NUMBER only Specify the value against which the input value will be compared The alarm will be activated only if this PARM analog difference is gt the value of STPT HYST OFF Hysteresis If hysteresis is desired specify the value H is aff ly th int at which Hysteresis NUMBER i es aitects only the point at which an alarm A high alarm will clear when the input is less than the setpoint minus the hysteresis value A low alarm will clear when the input is greater than the setpoint plus the hysteresis value A deviation alarm will clear when the input is less than the setpoint minus the hysteresis value D TM OFF Delay Time To prevent brief process upsets from triggering an alarm enter an alarm delay time If the Delay Time NUMBER alarm condition clears before the delay time expires no range is 0 to 240 seconds alarm will occur HOLD OFF Alarm Hold When this parameter level 1 ON the Alarm Hold coor alarm processing is disabled and the output is held i ONL See Table 9 14 On Label and Off Label Select the labels to be used Label inthe Summary display and by optional data storage On Label feature when the output is ON value 1 and OFF and value 0 OFFL Off Label 9 68 UC5300 Controller User Manual 5 00 Using Program M
35. Viewing program settings To review the current value of all function block parameters and other Program mode prompts use the procedure in Table 15 11 See Section 9 for descriptions of the prompts seen in Program mode ATTENTION This feature can be disabled in Programming mode If the instructions in this subsection do not work see your process engineer Table 15 11 Procedure for Viewing Program Settings Step Action 1 Select REVIEW from the Online menu PRG Al the first item in the Program menu will be displayed something but instead of selecting it for edit you are selecting it for viewing Use the A and W keys to scroll through the lists 2 Access all the prompts using standard navigation methods press ENTER to select 15 14 UDC5300 Controller User Manual 5 00 Storing and Loading Configuration and Calibration 16 Storing and Loading Configuration and Calibration 16 1 Introduction Overview The optional data storage interface feature lets you store controller configurations and calibrations on the PCMCIA card or load them from the card to the controller What s in this section The following topics are covered in this section Topic Page 16 2 Installing a PCMCIA Card 16 2 16 2 Storing and Loading Configuration and Calibration 16 4 5 00 UDC5300 Controller User Manual 16 1 Storing and Loading Configuration and Calibration 16 2 Installing a PCMCIA Card Intr
36. parameter used to specify the probe type UDC5300 Controller User Manual 5 00 12 2 2 Carbon Potential Option Limits and Accuracy Introduction The probe linearization equations used in this design have been verified against the oxygen probe manufacturers supplied tabular data Table 12 1 shows the ranges of that data The performance of the probes is specified only while the parameters remain within the Specified Performance Range in Table 12 1 Refer to probe manufacturers documentation for probe accuracy specifications However the equations yield continuous results while the parameters are outside the Specified Performance Range in Table 12 1 but within the Valid Working Range in Table 12 2 The function block will produce continuous values for C and Dewpoint while the parameters are outside the Specified Performance Range and within the Valid Working Range but no claim is made with respect to the accuracy of those values For example on a Furnace Control Corp s probe C values outside of the range 0 35 to 1 65 but within the range 0 00 to 2 00 are produced by the block but the accuracy is not guaranteed Table 12 1 Probe Manufacturers Specified Ranges PARAMETER SPECIFIED PERFORMANCE RANGE Advanced Furnace Marathon Super Atmosphere Control Corp Monitors Systems Inc before addition of the value of the FURN furnace factor Output of the C calculation parameter 1006 to 1207 Oxyge
37. scrolls through 0 to 9 and the minus sign if applicable For other digits scrolls through 0 to 9 In loop display increases alterable value For example if the loop is in Auto the setpoint can be increased If the loop is in Manual the output can be increased Accesses setpoint profile start advance hold reset operations Program Online Maint v v v v v v v v v v v v v v v v v v 5 00 UDC5300 Controller User Manual 6 15 Modes Menus Prompts and Keypad Basics Table 6 3 Key Functions continued Symbol Name Function Operating mode in which function applies Program Online Maint V DECREMENT e Moves cursor down a list menu e When entering the most significant digit of a number S v scrolls through 9 to 0 and the minus sign if applicable For other digits scrolls through 9 to 0 e In loop display decreases alterable value For example if V the loop is in Auto the setpoint can be decreased If the loop is in Manual the output can be decreased e Accesses setpoint profile start advance hold reset operations ENTER ENTER e Selects displayed menu item v 7 7 e Enters a changed value or parameter e f prompted to SAVE CHANGES saves changes made and returns to higher menu LEFT e When editing a number selects i lt A the digit to be edited DISPLAY DISPLAY e From any display or menu v v v accesses up to 10 online displays assigned
38. 11 To save the changes press ENTER To abandon the changes press MENU Either way you will remain in Program mode ready to edit Al2 12 To move back up the menu hierarchy press MENU The prompt will change to PRG AI this by pressing MENU again If nothing happens you really are at the first 13 At this point you are at the first item in the Program menu You can confirm item in the menu 14 To change to a different mode press A The SET MODE prompt will again be displayed UDC5300 Controller User Manual 6 19 Modes Menus Prompts and Keypad Basics 6 20 UDC5300 Controller User Manual 5 00 7 1 Using a Factory Configuration 7 Using a Factory Configuration Overview Factory configurations are built in control strategies with the necessary function blocks already programmed to pass the required data All factory configurations are stored in the firmware of every UDC5300 controller although not every controller has the I O hardware to support every Strategy This section provides details about the available factory configurations and about how to tailor them to your application If you specified a factory configuration during model selection see Section 2 then the correct strategy will be loaded into memory before the unit is shipped All that will be left for you to do is program site specific values such as ranges and tuning parameters If you did not specify a factory configuration o
39. 14 5 RNGH CV PP parameter 9 40 RNGH CV SPLT A parameter 9 63 RNGH CV SPLT S parameter 9 60 RNGL CV PP parameter 9 40 RNGL CV SPLT A parameter 9 63 RNGL CV SPLT S parameter 9 60 ROLLOVER SET AED prompt 17 6 ROLLOVER SET TRND prompt 17 5 RRIN SP block parameter 11 3 RS 422 485 network See serial communications RST CV ITIMER parameter 9 54 RST CV PP parameter 9 39 RST CV PTIMER setup parameter 9 57 RST CV TOTL parameter 9 52 RST Pretune COMP prompt 13 4 RST UNIT Maintenance menu item 19 7 RST1 LP parameter 9 18 15 4 RST2 LP parameter 9 19 15 4 RTD inputs specifications 2 4 wiring 4 11 RTE Pretune COMP prompt 13 4 RTE1 LP parameter 9 18 15 4 RTE2 LP parameter 9 19 15 4 RUN DIAG Maintenance menu item 19 7 S scan frequency programming 9 82 SDAY CV PTIMER setup parameter 9 57 security bypass procedure B 1 entering password 6 9 programming 9 78 9 79 self diagnostics initiated by operator 19 7 viewing messages 15 10 15 11 SER COMM Program menu prompt 18 2 serial communications termination jumper settings 18 3 18 5 wiring 4 15 SET AED DS SETUP prompt 17 4 17 6 SET AO Online menu item 15 13 SET DAY SET CLK prompt 9 80 SET FRMAT SET CLK prompt 9 80 SET HRS SET CLK prompt 9 80 SET MIN SET CLK prompt 9 80 SET MODE SECURITY prompt 9 78 SET MON SET CLK prompt 9 80 SET PARM SECURITY prompt 9 79 SET PT accessed with SET
40. 2 or 4 Type Form C and Form A in pairs Max Switch Current 14 5 NO NC Amps 120 Vac resistive Max Switch Voltage 265 Vac Max Switch Power 200W dc 2000 VA ac Max Carrying Current 2 Amps 250 Vac 5 Amps 120 Vac 2 Amps 24 Vdc Control loops Number 1 or 2 Algorithms Standard PID Advanced PID Ratio Cascade Primary Cascade Secondary Split Output Heat Cool DIAT On Off Calculations 16 standard 11 types Constants 9 standard Alarms 4 standard Types high low high rate low rate deviation Autotune Pretune Setpoint Number of segments 16 oes Event outputs 2 Data storage Media SRAM PCMCIA card 256K 512K 1M Points Stored up to 6 Storage Rate 1 second to 3600 seconds Alarm History 100 records Event History 100 records Diagnostic History 100 records Requires Honeywell SDA software for review and analysis Setpoint Profiles Local storage Unit Configuration Local storage or with Honeywell SCF software 2 6 UDC5300 Controller User Manual 5 00 Specifications and Model Number Table 2 1 Specifications continued Performance Capacities Communications Type RS 485 multidrop Honeywell Instrument Link protocol or Modbus RTU Optional 31 units maximum Connection 2 twisted pairs with shield Distance 600 meters 2000 feet Baud Rate 1 2 K 2 4K 4 8K 9 6 K 19 2 K 38 4 K baud Parity Selectable odd even none Table 2 2 Analog
41. 20 CN9 OV AO1 TYPE VAT AO1 INLL 0 AQ1 INHL 100 AO1 OVLL 0 AO1 OVHL 5 5 00 UDC5300 Controller User Manual 7 23 Using a Factory Configuration 7 4 10 Configuration 10 110 PID Ratio Control with Time Proportioned Relay Out Description This strategy keeps the controlled variable in ratio with the wild variable Both variables are supplied as linear analog inputs each served by an analog input AT block One relay is used to provide a time proportioned output A DAT Duration Adjusting Type analog output AO function block interfaces between the loop LP block and the discrete output DO block associated with the time proportioned relay In this application the AO block is not associated with analog output terminals Basic diagram Controlled Analog Input 1 Be 0 100 PID i Loop 1 Wild Analog Input 2 Ratio ariable 0 100 Bias Wiring diagram Alt Controlled SIGE dE Mi Cl Ra H R SHRI ES Es SRS ask OQ Oq _O QO FAIR OQ O Oy OQ O LO 7 Al2 Wild 7 24 UDC5300 Controller User Manual C Relay 1 Time Prop DO1 5 00 Using a Factory Configuration Programming diagram AO3 TYPE Al1 TYPE LP1 PV Al1 OV DAT LINEAR LP1 TYPE AO3 INP LP1 OV AO3 OUT
42. 9 12 9 14 LP block description 5 16 example of use with carbon potential CV 12 11 parameters See loops M MAIN FRQ Maintenance menu item 19 8 Maintenance mode outputs state 6 2 submenus 6 7 tasks 1 9 MANUAL AUTO key conditions for using 14 5 disabling 9 25 9 79 functions 6 17 Marathon Monitors Co 12 3 12 4 MASTER SECURITY prompt 9 78 math CV 9 43 9 45 memory card See PCMCIA card memory clearing 19 7 MENU key functions 6 15 menu use 6 10 messages 13 5 17 13 21 1 21 9 MIN CV PP parameter 9 39 Modbus 4 15 18 2 model number 2 9 2 12 model selection guide 2 9 2 12 modes of operation 6 2 MOFF AO DAT parameter 9 32 MOFF LP parameter 9 23 MOFF SET AO prompt 15 13 MON AO DAT parameter 9 32 MON SET AO prompt 15 13 mounting the unit 3 3 3 4 MRST LP parameter 9 20 15 5 N noise suppression 4 4 O ODPT AI custom parameter 9 9 ODPT AI standard parameter 9 4 ODPT AO CAT VAT parameter 9 29 ODPT CV CARBON parameter 12 4 ODPT CV ITIMER parameter 9 54 ODPT CV MATH parameter 9 43 ODPT CV PP parameter 9 39 ODPT CV SPLT A parameter 9 61 Index 4 UDC5300 Controller User Manual 5 00 ODPT CV SPLT S parameter 9 59 ODPT CV SSEL parameter 9 41 ODPT CV TOTL parameter 9 51 ODPT LP parameter 9 16 ODPT SP block parameter 11 3 OFF label choices 9 36 OFFL AL parameter 9 68 OFFL CV CMPARE parameter 9 65 OFFL CV INV pa
43. Introduction Any alarm can be programmed with a delay preventing nuisance alarms from brief process upsets Alarm hysteresis time can also be configured to prevent an alarm from clearing from the display too quickly even if the alarm condition is corrected Setpoint profiles The optional Setpoint Profiler feature lets you configure a profile with up to sixteen ramp or soak segments by entering a setpoint and time for each segment The setpoint generated by the profiler can then be used by either loop Two event bits can be configured to be turned ON or OFF for the duration of a segment permitting discrete actions to be tied to individual segments A deviation hold function is configurable This puts the profile execution on hold if the process variable strays from the setpoint by more than a user specified amount A dedicated setpoint profile key provides quick access to online operation of the profiler Every operator display provides indication of the status of the profile execution Profiles can be stored in the removable PCMCIA card for error free recipe loading Use of the Setpoint Profiler is described in Section 11 Carbon potential The carbon potential option makes a special calculated value type function block available that uses the input from a zirconia oxygen probe the probe temperature and other user supplied values to calculate a percent carbon output as well as the dewpoint and the highest furn
44. Notes ALGR STD A custom curve is not required for this input so use the standard I _ input algorithm and set the type to linear TYPE LINEAR ODPT XXXXX X Set the decimal point to the appropriate position RGLO 0 0 Specify the input range RGHI 1250 0 D ID INDIRE Specify indirect input you will be prompted to assign engineering units to a specific millivolt or voltage span see below CKLO 0 0 Specify the actual low and high values of voltage used for this Indirect measurement as well as the unit of measure in which the CKHI 1250 0 range values are expressed CKUN MV Temperature input from oxygen probe The temperature input from the thermocouple in the oxygen probe is processed by an AI function block In our example the field wiring goes to the AI2 input terminals Table 12 5 shows the programming for the AI1 block in Figure 12 1 If you want to have this temperature value available for display while the controller is online you must program a CV block as shown in Table 12 6 Then during programming of the display cycle see Section 9 select this calculated value for display on a PVCV display for the associated loop Table 12 5 Al2 Configuration for Oxygen Probe Temperature A custom curve is not required for this input so use the standard Input algorithm and set the type to match the thermocouple inthe oxygen probe RGLO 0 0 Spec
45. Quantity 22 2 7 Membrane Keypad fF o 22 3 3 Switch Caps 8 4 51197835 501 PC Molding Replacement Kit kit includes Figure Detail Part Description Quantity 225 14 PC Molding a 5 51197838 501 Pivot Arms Replacement Kit kit includes Figure Detail Part Description Quantity 22 2 49 Upper and Lower Pivot Arms 1 6 51197842 501 CPU Board Replacement Kit kit includes Figure Detail Part Description Quantity 225 27 046999 CPU Board za Figure Detail Part Description Quantity 22 5 28 046993 Single TC EMF RTD Input Board a 22 2 UDC5300 Controller User Manual 5 00 Parts List Figure Detail Part Description Quantity 225 28 047251 Three TC EMF RTD Inputs Board a Figure Detail Part Description Quantity 22 5 29 046989 Power Supply with Two Relay Outputs Board 1 Kit includes 22 4 8 Rear Terminal Block i 22 9 32 046925 RS 485 Serial Communications Module 1 22 9 33 15 16 Large Plastic Standoffs 4 22 5 34 Serial Communication PROM U3 Figure Detail Part Description Quantity 22 5 31 046995 PCMCIA Memory Card Interface Board 1 5 00 UDC5300 Controller User Manual 22 3 Parts List Figure Detail Part Description Quantity 225 31 Piate 11 Kit includes Figu
46. Rman I HL Rman Rman AO Rman I cuca I chea W chea W chea chea chea I Notun W orun tun prun E orun A prun A orun I oxy I ML oky W ok oxy ky W ky Il sese I sese sese sese II sese W spese I i ams I ams fl ams fl ams ams fl ams I I ove I ove I lo acr fl acr I Ho acr W iacr W iacr DH iacr Wo iacr M i ast I tl morr I Rum fl Rum I Rum Rum EO Rum AO Rum Rum I fl eao W eao eao eao W eao eao W eao wao I 5 00 UDC5300 Controller User Manual 9 15 Using Program Mode to Configure Function Blocks and Features Loop Prompt Descriptions The loop prompts are in Table 9 8 in the order in which they are displayed Not every prompt applies to every loop type Refer to the Applies To column or to Table 9 7 to determine whether a particular prompt applies to a loop type Table 9 8 Loop Prompt Descriptions Prompt Full name Applies To Range Selections Inout Decimal Position XX XXXX XXX XXX XXXX XX XXXXX X XXXXXX point to the position to be used in the input value Input Decimal Position Move the decimal provided to the control loop Output Decimal Position XX XXXX XXX XXX point to the position to be used in the loop s Output Decimal Position Move the decimal output value OV Process Variable NUMBER PARM analog loop Select the function bloc
47. Wiring diagram Actuator Voltage Using a Factory Configuration AO1 OOO OOO Oe alejalejalo g e alejale ele e e alejale ele e e Al2 Al3 Programming diagram Actuator Voltage All TYPE LP1 PV LP1 TYPE AO3 INP LP1 OV LINEAR Al1 OV STD O roz LP1 FB AO3 BC AO3 TYPE PP Al2 TYPE AO3 SLWR Al2 OV AO3 PA PP LINEAR AO3 INC DO AO3 DEC DO2 CN9 IN AO1 INP 20 CN9 OV AO1 TYPE VAT AO1 INLL 0 AO1 INHL 100 AO1 OVLL 0 AO1 OVHL 5 oo AI3 TYPE LP2 PV LP2 TYPE AO4 INP LP2 OV LINEAR AI3 OV DIAT t LP2 FB AO4 BC 5 00 UDC5300 Controller User Manual AO4 TYPE PP AO4 PA DIAT AO4 INC DO3 AO4 DEC DO4 7 55 Using a Factory Configuration 7 4 27 Configuration 27 227 Two Independent PID Loops Each with Direction Impulse Adjusting Relays Out Description Two independent loops each provide PID control with direction impulse adjusting output using two relays for each loop For each loop a linear input served by an analog input AJ block supplies the process variable An analog output AO block with its type set to PP position proportioning and its
48. action and input will not be configurable in DO programming Labels are still configurable 10 4 UDC5300 Controller User Manual 5 00 Position Proportioning Output Setup and Calibration Table 10 1 Block Configuration to Implement PP Shown in Figure 10 1 Program the CN block specified in Step 4 as the source of the input to the AO providing the 1 V to power the slidewire feedback The input of the CN block must be a number that when applied to the AO block s output range will result in the AO block making a constant 1 V available at its output terminals In our example the output range for AO1 is 5 volts Therefore our constant block is configured CN9 IN 20 20 of 5 V 1V CN9 INLL 20 CN9 INHL 20 CN9 DEST OFF because we do not want the CN block to write the 20 to another block AO1 will read the 20 from CN9 OV 5 00 UDC5300 Controller User Manual 10 5 Position Proportioning Output Setup and Calibration 10 3 Wiring the Controller for PP Introduction For the position proportioning output to work as anticipated the connections to the I O terminals must match the usage of the associated function blocks ATTENTION Honeywell 10260 series drive units provide motor winding noise suppression If your drive unit does not suppress winding noise wire a capacitor 22 uF 400 Vac to the INC line and another to the DEC line and a resistor 22 ohm to the neutral or ground connection Honeywell part 0233
49. if desired 5 To change the number press the W key to scroll through the number from 01 to 99 When the number you want is displayed press ENTER This initiates the storing operation display reads STORE COMPLETE you can press MENU to exit the function Remove and label the card 6 During the storing operation the display will read FILE STORING When the UDC5300 Controller User Manual 5 00 Configuring and Using Setpoint Profiler Procedure for loading a profile 5 00 Loading a profile transfers profile data from a SRAM PCMCIA card to the controller s memory The procedure for loading a profile is provided in Table 11 4 This procedure assumes that you know how to lift up the front of the controller and insert a PCMCIA card If you need instructions for those tasks see Section 16 Table 11 4 Procedure for Loading a Profile and close the bezel Select PROFILE from the Online mode Menu and advance to the PRF 1 Put the PCMCIA card containing the profile to be loaded into the controller LOAD menu selection Press ENTER to start the procedure The display will change to LOAD XXXXXX where XXXXXX is the name of a file on the card 2 To select a different file press the DECREMENT VW key to scroll through all the names of all the files on the card 3 When the desired file s name is display initiate the loading by pressing ENTER display reads LOAD COMPLETE you can press MENU to
50. prompts to specify the source of the inputs to the CV Input 1 ese function block through PARM analog Inputs 3 through 8 are not used if the signal selection INP8 action is based on a discrete switch See ACTN selection DIS SW below Input 8 5 00 UDC5300 Controller User Manual 9 41 Using Program Mode to Configure Function Blocks and Features Table 9 18 CV Signal Select Prompts ACTN Action Select the action type to be used as the basis for signal selection HIGH LOW AVG MIDDLE High selects the signal with the highest value Low selects the signal with the lowest value Average computes an average of all the input values Middle selects the median input value If the number of inputs is even then the output equals the sum of the two middle values divided by two F GOOD First Good selects the first signal to reach the function block in case of input failure Input failure is recognized by the controller when the input is more than 10 out of range or when the controller detects lack of continuity This bad input status is propagated to any other function blocks using the input or the failsafe value for the input will be used if enabled FIRST GOOD will stop the propagation of the bad input status and presents a known good output from the CV block ANA SW Analog Switch selects the signal associated with the input whose number equals the value specified for ASEL For exampl
51. uses eee 2 1 2 1 NEVEN see secant gs ayes seen ccianc sige ou oeese ani A sue eciae ante ase T 2 1 22 SPE AA EN EEN oe acre he de a 2 2 23 Mode Selection Gude aa sade sscassniaus ane N ein eae 2 9 3 UNPACKING PREPARATION AND MOUNTING cc ccceesesseseeeeeeeeees 3 1 duh COV OEVICW unisona a n tie cece aaa dence asta aa aa aaa 3 1 332 Unpack and Prep ari asc a a ra e 3 2 3 3 MOUNU Va lca Socair a E E E Urea we corpse ee 3 3 4A WIRING tcc cc a S 4 1 4 1 OV CLOW EE E EE E Er A A EE E E S EN E RE 4 1 4 2 General Wire Practices seende a a E RAR 4 2 4 3 DPE CUM TINS OC 103 i RO i558 5 MESSE SEERE RENEE REDER tgeeneusessauecansmaastateaeenesuussanet cu sasuiewa aeossnossantesarcaananates 4 4 5 PLANNING FEE stances bens a asacnatenercsanesaresareues 5 1 5 1 RV SEY BON SEE DER sche ee castes bed ha wnsoeaacusiosciaee caste cet ae wnaos eens ee EEN ANE ELSE anes 5 1 a Function Block Capabilities neaei E 5 2 SAW dt ay PU CMON BLOCK 1S ise le L 5 2 5 2 2 How Function Blocks Work Together cccccccccccccccceccesessseseeeececeeeeeeeeeeeaaussasssseseeeeeeeeess 5 2 2 5 F UNCHOM 1OCK C OMPlOMeit nc aceiicateen actus eben ald a 5 5 5 24 Brief Descriptions of Block VV Pes assisen er reen eres 5 5 5 2 5 Summary Or Outputs A Vallable es arsen na a eee ee 5 21 5 3 Factory Conlisuration Basics aessa esie a Aaeeeiai de an eie heniek anainn 5 23 5 4 Factory Conliguration Appl Cations sans een a ial ae esse loggen 5 24 SI asks Tha
52. 1 typical 0 8 4 0 002 0 003 18899 8814 340to 1800 172to 982 0 1 typical 1 4 81 0 002 0 003 18894 9014 752102552 400t0 1400 10 1 typical 1 7 1 0 0 002 0 003 18894 0579 752102552 400101400 0 1 typical 1 7 1 0 0 002 0 003 Spectray 18885 1832to 3452 1000101900 0 1 typical 1 6 0 9 0 005 0 009 Spectray 18886 1833t0 3452 1001to 1900 0 1 typical 1 6 0 9 0 005 0 009 Spectray 18886 1 1292to 2912 700to 1600 0 1 typical 1 6 0 9 0 021 0 037 Spectray 18885 1 1292102912 700t01600 0 1 typical 1 6 0 9 0 005 0 009 Spectray 18885 2 80610 1400 430 to 760 0 1 typical 0 6 0 3 0 005 0 009 18874 0578 752102552 400101400 0 1 typical 1 7 1 0 0 083 0 150 18875 0579 752102552 400101400 0 1 typical 1 7 1 0 0 083 0 150 1 Italicized values indicate overall input range HE 2 IPTS 68 2 8 UDC5300 Controller User Manual 5 00 Specifications and Model Number 2 3 Model Selection Guide Introduction All UDC5300 Controllers are supplied with one current output CAT and two relays When factory configuration models are specified the current output or relays may be used by the configuration For some factory configuration types additional hardware may be needed as specified in the notes If relays or current outputs are not used by the configuration they are available to perform other functions in the contr
53. 111 PID with Position Proportioning Relays Oult cccccceees 7 26 7 4 12Configuration 12 112 PID Ratio Control with Position Proportioning Relays Out 7 28 7 4 13Configuration 13 113 Backup to Primary Controller or PLC Uses Position PROPOLMIOMING RELAYS OU seede ad eee a iene enon ah ha se ads 7 30 7 4 14Configuration 14 114 PID with DIAT Relays Out cc ccccsssseesseseeeeeeeeees 7 32 7 4 15 Configuration 15 115 Single Loop with ON OFF Relay 1 0 00 ccccesssssseeseeeeeeeeeees 7 33 7 4 16Configuration 16 216 Cascade PID with Current Output 20 0 0 cceseeeseseeeeeeeeees 7 34 7 4 17Configuration 17 217 Two Independent PID Loops Each with Current Output 7 36 7 4 18Configuration 18 218 Two Independent PID Loops One with Current Output and One with Time Proportioned Relay Out 2 0 ccccccccssssseseseeeeececeeeeeeeeeeaaaaseeeeees 7 38 7 4 19Configuration 19 219 Two Independent PID Loops One with Current Output and One with Position Proportioning Relays Out cccsssssseseeeseeeceeeeeeeeseeaeaseeeeeeees 7 40 7 4 20Configuration 20 220 Two Independent PID Loops One with Current Output and One with Direction Impulse Adjusting Relays Out cc ccecessssseeeeeeeeeeeeeeeaeeeeeeeeees 7 42 UDC5300 Controller User Manual 5 00 7 4 21 Configuration 21 221 Cascade PID with Time Proportioned Relays Out 0 7 44 7 4 22 Configuration 22 222 Two I
54. 29 INHL CN parameter 9 70 INLL AO CAT VAT parameter 9 29 INLL CN parameter 9 70 INP AL parameter 9 68 INP AO CAT VAT parameter 9 29 INP AO DAT parameter 9 31 INP AO PP parameter 9 33 INP CV INV parameter 9 58 INP CV PP parameter 9 39 INP CV SPLT A parameter 9 61 INP CV SPLT S parameter 9 59 INP CV TOTL parameter 9 51 INP DO parameter 9 37 INP1 CV CMPARE parameter 9 64 INP1 to INP8 CV LOGIC parameters 9 46 INP1 to INP8 CV MATH parameters 9 43 INP1 to INP8 CV SSEL parameters 9 41 INP2 CV CMPARE parameter 9 64 instrument address 18 2 interval timer CV 9 54 9 55 inverter CV 9 58 ISLW AO CAT VAT parameter 9 30 ISLW AO DAT parameter 9 31 ISLW LP parameter 9 21 15 5 ISTL Pretune COMP prompt 13 4 K key functions 1 7 6 8 6 10 6 15 6 17 L label choices 9 36 LAG AI custom parameter 9 10 LAG AI standard parameter 9 5 latches releasing 18 5 LBAD LP parameter 9 26 LEFT key functions 6 16 loading configuration setpoint profile etc See name of item to be loaded logic CV 9 46 9 50 LOLI SP block parameter 11 3 loop block See LP block loop error indicators 21 5 loop ranges in factory configuration 7 5 loops displaying output 14 4 feedback requirements 8 6 9 13 9 23 13 6 and math CV block 9 44 and split output 9 60 9 62 and split output 9 14 pretuning 13 2 13 5 programming 9 12 9 26 special issues
55. 5 21 Planning Table 5 3 Function Block Output Designators Function Function Block Output Output Name Output Block Name Code Type Code CV Calculated Value OV Output Value analog PV Process Variable analog A n Analog Output n analog BC Back Calculation analog D n Discrete Output discrete OS Output Status discrete Input to the following CV types Peak Pick Totalizer SY System Parameter RT Reference Junction Temp analog AG Alarm Global discrete AH Alarm High discrete AL Alarm Low discrete DF Diagnostic failure not used discrete DG Diagnostic General discrete SF Storage Full discrete SW Storage Warning discrete AX Analog Safe Parameter analog DX Discrete Safe Parameter discrete SP Setpoint Profiler OV Output Value analog PV Process Variable Loop1 Deviation Hold analog SN Segment Number analog SH Hold Status discrete SE End Status discrete SA Active Status discrete SI Active or Held Status discrete SR Ready Status discrete E1 Event 1 Output discrete E2 Event 2 Output discrete NOTE If an output code is programmed as input but is not available it will not be saved 5 22 UDC5300 Controller User Manual Planning 5 3 Factory Configuration Basics What a factory configuration is A factory configuration is a built in control strategy A factory configuration strategy uses the same function block types that are available for freeform programming Whe
56. 5300 deviation of process i variable E a 4 setpoint D El 2 Ke Program status Active setpoint 1 or 2 Keys 24207 o Accesses up to 10 on line displays DISPLAY i o Changes controller to on line mode MANUAL o Toggles loop between automatic and manual modes or between AUTO remote manual and manual modes when remote manual is ON o Moves cursor up a menu or list of choices o Increases the setpoint output or configuration values displayed o Accesses on line mode menu o Moves cursor to first item on menu o Backs cursor out of a menu to next higher menu level o Exits menu without saving changes if pressed when prompted to save changes o Accesses setpoint profile displays o Selects the digit to be changed o Moves cursor down a menu or list of choices o Decreases the setpoint output or configuration values displayed o Selects displayed menu item o Enters a changed value or parameter ENTER 3 i o Saves changes made and returns to higher menu if pressed when prompted to save changes Figure 1 2 Display Indicators and Key Functions 5 00 UDC5300 Controller User Manual 1 7 Introduction 1 3 Overview of Tasks in Each Mode Menus for every mode and task For your convenience a menu is provided to perform all tasks in each mode Online Program and Maintenance Online mode tasks Online mode tasks include tuning the control loops defining and operating a setpoin
57. AO block However other analog output parameters such as a calculated value can be used as the AO INP When doing CAT or VAT control the output value OV of AOI and or AO2 is automatically supplied as a field signal at the screw terminals associated with each block Refer to the terminal label on the controller This OV can also be read by another block such as an alarm block that is programmed to use the AO OV as its input A back calculation value BC is also provided by the AO block as well as a special output S2 that retransmits the process variable AO s input Although in DAT control a discrete output DO block is used to implement the control through a relay the DO is not programmed to read the AO OV during configuration of the DO block Instead the association between the AO and the DO is made during AO configuration The AO has an OUT parameter for this purpose During AO programming the numbered DO associated UDC5300 Controller User Manual 5 00 Planning with the relay to be used for DAT control is assigned to AO OUT This means that particular DO is no longer available for other purposes such as alarm annunciation In PP control including its sub type DIAT two relays are needed so two DO blocks must be associated with the AO During AO programming the AO parameters INC increase output and DEC decrease output are used to specify the numbered DO blocks associated with the screw terminals for the relays T
58. BC FB LP2 BC 5 00 UDC5300 Controller User Manual 7 35 Using a Factory Configuration 7 4 17 Configuration 17 217 Two Independent PID Loops Each with Current Output Description Two independent loops each provide basic PID control For each a linear input served by an analog input AI block supplies the process variable to a standard PID loop The output of each loop is through a CAT current adjusting type analog output AO block Basic diagram Analog Analog Input 1 PID Output 1 PV Loop1 0 100 4 20 mA Analog Analog Input 2 PID Output 2 PV Loop2 0 100 ai Wiring diagram n T L1 L2 N 7 36 N N S S S S S ODIOLODI ODIOLODI UDC5300 Controller User Manual 5 00 Programming diagram All TYPE LINEAR Al2 TYPE LINEAR 5 00 Using a Factory Configuration LP1 PV Al1 OV LP1 TYPE AO1 INP LP1 OV STD LP1 FB AO1 BC LP2 PV Al2 OV LP2 TYPE AO2 INP LP2 OV STD LP2 FB AO2 BC UDC5300 Controller User Manual 7 37 Using a Factory Configuration 7 4 18 Configuration 18 218 Two Independent PID Loops One with Current Output and One with Time Proportioned Relay Out Description Two independent loops each provide basic PID cont
59. BC AO4 TYPE PP AO4 PA DIAT AO4 INC DO3 AO4 DEC DO4 5 00 UDC5300 Controller User Manual 7 51 Using a Factory Configuration 7 4 25 Configuration 25 225 Cascade PID Position Proportioning Relays Out Description This strategy provides cascade control in which the setpoint of the secondary loop is read from the output value of the primary loop Each loop uses a linear PV input via an analog input AI block Two relays are used to provide a position proportioning output An analog output AO block with both its type and its positioning algorithm set to PP position proportioning interfaces between the secondary loop block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO block is not associated with analog output terminals An analog feedback signal from the positioner s slidewire is received at AI2 The feedback is powered by a constant 1 V from the terminals associated with AOI and its VAT voltage adjusting type AO function block having an output range from 0 to 5 Because the input to the AO is 20 from a constant CN block a steady 1 V out is achieved 20 of the 5 V range Basic diagram Analog Input 3 PV 0 100 Output 3 INC Relay 1 PID sg Analog Input 1 PID ree 0 100 Loop1 DEC Relay 2 A Position Analog Input 2 Proportioning Slidewire Feedback Ana
60. CT NE 14 1 viii UDC5300 Controller User Manual 5 00 14 2 Primary Display Descriptio Mesir EE E 14 2 14 3 How to Use Primary Displays 60 solist eana a a a 14 5 15 USING ONLINE MENU FUNCTIONG 0 cccceesseeeeseeeeseseesesenseeeenseeeneeeenees 15 1 15 1 Introdu Oisen tact ie et se sivas soe seat ask tatetesncmecea tue seauasuhea usec 15 1 15 2 Tuning a Loop and or Toggling the Setpoint 0 cc cccsssssssssseeeeeecceceeeeessaaessssseeseeeeeeeeees 15 3 15 3 Viewing Displays in the Summary Group sssssesssseeeccceeeececeaaeeeesssseeeeeceeeeeeeeeeseaeeessess 15 7 KDE E E ase cache eee SENE SS E FRE te ue ea E a Secrets eee a ee eee tenet 15 8 DDD I DIENOSE Sisters hea tate aati ARENSE RES SENDE BRS REESE KERES GS SEERE SEE LEE SENERE TRE SEERNES ERE PRESS 15 10 15 4 DATEN ESBEN ERR RAE SEE SEE ES ES FEED SEE EET N 15 11 15 5 ReViewine Prosraminih aen a N 15 14 16 STORING AND LOADING CONFIGURATION AND CALIBRATION 16 1 16 1 Modic CET isha sees cee bee a Te a anc iat tint te at 16 1 16 2 Installs a PC NIC TAG ai sner bene Machetes recent GE 16 2 16 3 Storing and Loading Configuration and Calibration c cccesesssescccceceeeceeeeeaaassseeeeeeeeees 16 4 oe i Mars 07 ar o Gir a HERRERNES EDB tel E E renee E terre Neeser tir ERE SED ery vetree te Nec rir erne nee ee 16 4 1632 Toadine MONTE at ssssletehotsak acces aati sot Sccated ER SOLER SEERE SEES ENE T NSE a SD ETE SEG ESS DEN 16 5 172 STORING DAT
61. CV block Input Decimal XXXX XX Position XXXXX X XXXXXX ODPT XX XXXX Output Decimal Position Move the decimal point to XXX XXX the position to be used in the output value provided by Output Decimal XXXX XX the CV block Position XXXXX X XXXXXX INP OFF Input NUMBER Typically this is the output value OV of a Split Output Input Specify the source of the analog input type of loop UDC5300 Controller User Manual 9 59 Using Program Mode to Configure Function Blocks and Features Table 9 28 CV Standard Splitter Prompts Prompt Range Selections Definition Full name FB1 AOn BC Feedback 1 and Feedback 2 Specify the source of the back calculation value BC of the analog output Feedback 1 LPn BC assigned to the A1 output Feedback 1 and A2 output FB2 CVn BC Feedback 2 Feedback 2 OVDB OFF Output Value Deadband Specify the deadband value If the value of INP is less than or equal to this Sana NUMBER percentage of the input range both A1 and A2 split eadband range is 0 to 10 of the outputs will remain at zero input span RNGL OFF Range Lower Limit and Range High Limit Enter the output s range when displayed as a trend with sah i NUMBER Honeywell SDA software RNGH The output is not clamped nor does it flash when Range High the output value is outside the range Limit 9 60 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9
62. Directive Conformance of this product with any other CE Mark Directive s shall not be assumed ATTENTION The emission limits of EN 50081 2 are designed to provide reasonable protection against harmful interference when this equipment is operated in an industrial environment Operation of this equipment in a residential area may cause harmful interference This equipment generates uses and can radiate radio frequency energy and may cause interference to radio and television reception when the equipment is used closer than 30 m 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 UDC5300 Controller User Manual 5 00 Contents ts INTRODUCTION cairida ee tent Eee rn en er 1 1 1 1 Fatores nd Benes la alle henne nen ne E eee 1 1 t2 Operator tere aa i arne nn ere S 1 6 1 3 OVerview OF Tasks in Paci MOGC aires E N tnd ge ERE U SENE EREE EG 1 8 1 4 Overview of Function Block Programming Concepls ccccsccceceeceeeeeeeeeeeesaeesessseeecees 1 10 LAT hata Punic ion Block IS sa see oes oh netted ass s ones ne Greene Ade cians sataniGinanislenss 1 10 1 4 2 How Function Blocks Work TOERE ords a a a eased tes 1 10 1 5 Overview of Installation Configuration and Startup Tasks ccccccccccccsssssseseseseseeeees 1 11 2 SPECIFICATIONS AND MODEL NUMBER
63. EUT a RES BEREDT FO SESEE ERE 8 12 9 USING PROGRAM MODE TO CONFIGURE FUNCTION BLOCKS AND FEATURES LEE En rodent rina ee ere ere eee 9 1 9 1 Fal oe 7e UCC ao 5 SE SEERE en Mice Nr ES Nie RE at ARE HNTE ERR Nec Cam ce RT NE RE So ae rn ene 9 1 92 Pro Sraimining Analog pits cen cach ne ads a e Rene Re ER EESERES 9 3 9 3 Proeraiminine Loop BIOCKS assustei aa 9 12 9 4 Programming Analog Outputs eeki a heh enhe k ass eldre 9 27 9 5 Proeramiming Discrete Nits eee n E 9 35 9 6 Programming Discrete Output Relays 2 0 0 ccccsssssesssseseeececceeeeeeeeeasaaeesesseeeeeeeeseseeeeeaaas 9 37 9 7 Programming Calculated Vales sea a E RER aL SALE 9 38 ON Peake PEKIA PE iera saa ERR SEERE SENE STEELERS ENDE e ead saa SEE ERE SEERNE EET E ENS SERENE Er 9 39 SERRA CN Stenal Select SSE SEGS ES EESEL na SERE SERENE RES EEE ERE ERNE REDE SORTERER TREERE 9 41 ITIC Math Operator MA TH eia eae eden a ADAG 9 43 OTA CN TOSCA LOGIC hesseni E E E S 9 46 PRIN TO ZEN TOTE henee a a heels 9 51 O TON Interval UME LIMER aa A 9 54 OT CN Periode Me P M E raa an A ene ed gs sd 9 56 FTON TOVE od Ch ae re Ene EA OE Mt ene EOS USES SANE ES ORR Toe 9 58 979 CV Standard Splitter Output SPL T S eats testes eks redder E Rs taenke dan laid 9 59 97 AOCY Advanced Splitter Output SPE TAA cicetiiseicnnieieiniicn eno 9 61 O71 CV Compare C MIPA RE faena es ea ler a a N 9 64 9 8 Prosranmnmi ne Ala en reale a ele ete nee neces 9 67 9 9 PEO OF Aim EMH CONUS CAS rte atcha ter ERE NNE E
64. FARS ISLA MMS re ya nt V ALOU eee ot wich ERE TEE E EAE ERE E E E ET 7 6 7 4 Detailed Information About Each Strategy eeeesesssssssoeeeeerersssssssssssseeeerrersssssssssssssseeeee 7 7 7 4 1 Configuration 01 101 PID with Current Outpul ec ccccccccccceeeeeeeeeeeaaaseeeeseeeeeeeees 7 8 7 4 2 Configuration 02 102 Heat Cool with Current Output for Each cc seeeeeeeeeeeeeees 7 9 7 4 3 Configuration 03 103 Heat Cool with Current Out for Heat and Time Proporiomed Relay 10f COOlsgiie ict iuic tess ED ahercd A 7 10 7 4 4 Configuration 04 104 Heat Cool with Current Out for Heat and Position Proportiomine Relays for COO Siese cys en hanen bedet enkelte meted ee aber nud 7 12 7 4 5 Configuration 05 105 PID Ratio Control with Current Output ce eeseeeeeeeeeeeees 7 14 7 4 6 Configuration 06 106 Backup to Primary Controller or PLC Uses Current OO asses RES SN le eee E 7 16 7 4 7 Configuration 07 107 PID with Time Proportioned Relay Output 1 1 1 1 1 1 1 sseeceeereee 7 18 7 4 8 Configuration 08 108 Heat Cool with Time Proportioned Relay for Each 7 20 7 4 9 Configuration 09 109 Heat Cool with Time Proportioned Relay for Heat and Position Proportioning Relays for Coo cccccccccccccccccesssssseesseeeecceeeeeeceeeessaeeseseeeeeeeeeess 7 22 7 4 10Configuration 10 110 PID Ratio Control with Time Proportioned Relay Out 7 24 7 4 11Configuration 11
65. If it is not PRG Al then press the the INCREMENT A key The prompt SET MODE will be displayed on the bottom line The cursor wil be next to it A mode name will be displayed on the top line Press INCREMENT A or DECREMENT VF until the top line of the display reads PRGRM Press ENTER to select it The display will change to the first item on the Program menu PRG Al and the cursor will return to the bottom line To indicate that you want to program an Al block press ENTER The text on the bottom line will change to PRG Al1 To select Al2 for edit press A or W until the display reads PRG Al2 Press ENTER to select tt The display will change to show Al2 TYPE the prompt for the first Al parameter on the bottom line and the currently assigned value or choice on the top line The cursor will remain on the bottom line To edit the Al2 input type press ENTER to go into edit mode The cursor will move to the top line When T is displayed on the top line of the display press ENTER This selects T The cursor returns to the bottom line The prompt will change to Al2 ODPT the next parameter available for To move on to the next parameter use A or V configuration UDC5300 Controller User Manual 5 00 5 00 Modes Menus Prompts and Keypad Basics 10 To exit the menu press To exit the menu press MENU The display will read SAVE CHANGES
66. If you want to configure the second loop press the DECREMENT VW key to change the prompt to PRG LP2 then press ENTER Maintenance and Online modes The same principle applies in Maintenance mode when selecting the analog input or analog output to calibrate and in Online mode when selecting an item from multiple instances such as tuning parameter sets There can be two Use the DECREMENT VW key to display the item to be edited then press ENTER 6 3 2 2 General Format of Displays Using Menus Value on top line prompt on the bottom Once an item has been selected from the top level menu and if necessary an instance of a numbered item has been selected the display changes The general format of displays used for programming and maintenance is to have a prompt eight characters maximum on the lower line of the display and the current value of the parameter or function represented by the prompt displayed on the upper line of the display six characters maximum Example For example in Program mode once you have selected an AI block to program you will see LINEAR Al1 TYPE In this case AI1 TYPE is the prompt and LINEAR is the current selection for the TYPE parameter for analog input 1 s function block The 1 after the AI is significant because the controller can use more than one function block of a particular type Therefore the particular instance of the function block type being edited is alw
67. In 1 analog Out 2 relays In 1 analog Out 1 relay Table 5 5 Single Loop Factory Configurations continued Control Type SPLIT PID with split output RATIO PID for ratio STD standard PID RATIO PID for ratio ADV advanced PID DIAT PID with Direction Impulse Adjusting Type output Input Signals analog PV and analog slidewire feedback from positioner analog controlled variable and analog wild variable analog PV and analog slidewire feedback from positioner analog controlled variable and analog wild variable and analog slidewire feedback from positioner analog PV and analog source of Remote Manual output value and discrete input for Remote Manual status analog PV Output Signals DAT for heat PP for cool UDC5300 Controller User Manual Special Features VAT output provides constant 1 V to power slidewire feedback VAT output provides constant 1 V to power slidewire feedback VAT output provides constant 1 V to power slidewire feedback VAT output provides constant 1 V to power slidewire feedback 2 relays used to transfer line voltage and slidewire power from primary s output circuits to UDC in case of primary failure proportioned relay for heat and position proportioning relays heat cool with time for cool with time proportioned relay PID ratio control out position proportioning
68. Input Accuracy Linear Types Input Range Accuracy typical Temperature Range mane mv Effects 25 mV to 25 mV 0 03 0 015 0 003 mV per C 75 mV to 75 mV 0 03 0 045 0 009 mV per C 200 mV to 1000 mv 0 04 0 48 0 037 mV per C 200 mV to 5000 mV 0 03 1 56 0 150 mV per C Field calibrated to 0 01 of span typical Field calibrated to 0 03 of span typical For CE compliance a connection is provided between protective earth ground TB4 Terminal 25 and earth ground for the communication connections TB1 Terminal 8 This wire will connect all of the suppression circuitry on the receive and transmit lines to the earth ground A triple shielded cable with a shield around each of the twisted pairs should be used for communications wiring The recommended cable is Belden 8728 80C The outermost shield must be connected to TB1 Terminal 8 5 00 UDC5300 Controller User Manual 2 7 Specifications and Model Number Table 2 3 Analog Input Accuracy Non linear Types F c Range F ae mV per F mV per C Thermocouples ITS 90 except where noted J 0 to 2790 18 to 1199 0o1 22 12 0 005 ooo9 K 0 to 2500 18 to 1371 loi 25 14 0005 looo E 450 to 241 268 to 152 06 137 7 6 0 005 o009 240 to 1830 151 to 999 R K T 300 to 1 184 to 19 a be magg Ba 0 to 700 1
69. ON after pretune has been completed After Starting Pretune After starting the pretune do not change adjust the loop mode loop output loop setpoint or operating mode If you do the pretune will abort See Pretune Abort Messages later in this section IDENT and CALC menus During IDENT and CALC status a TUNE indicator appears on all primary displays not on menus for the loop being pretuned Table 13 3 describes the Pretune IDENT and CALC prompts 5 00 UDC5300 Controller User Manual 13 3 Final Preparations for Bringing the Controller Online Table 13 3 Pretune IDENT and CALC Prompts PT TIME Elapsed time since pretune was started LP SP Current working set point value of the loop being tuned Setpoint LP OUT Current output value of the loop being tuned Output PT ABRT Select to cancel identifying and calculating and return to the stopped status COMP menu Table 13 4 describes the Pretune COMP prompts Table 13 4 Pretune COMP Prompts PT RST New reset determined by pretune Reset PT RTE New rate determined by pretune RATE PT ISTL Select to install the new pretune values into loop s tuning parameters specified by TSET in Table 13 2 Install PT ABRT Select to delete the new pretune values if you do not wish to install them Abort 13 4 UDC5300 Controller User Manual 5 00 Final Preparations for Bringing the Controller Online Pretune Abort messages One of the following me
70. Out Description Two independent PID loops each provide time proportioned relay output Each has a DAT Duration Adjusting Type analog output AO function block to interface between the loop LP block and the discrete output DO block associated with the relay In this application the AO block is not associated with analog output terminals Basic diagram Analog Input 1 PID V Relay 1 Loop1 0 100 Time Prop Analog Input 2 V sai be Relay 2 Loop2 0 100 i Time Prop Wiring diagram Alt S StS SHO QO Or OE O 11 OQ I O Orr LIN N D N N LOAD DO S 9419 S SIISII CO Load Supply OQ OHO Lo LOAD 45 S LOIS SH Load Supply Al2 7 46 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Programming diagram Al1 TYPE LP1 INP Al1 OV LP1 TYPE AO3 INP LP1 OV DO LINEAR STD AO3 TYPE DAT LP1 FB AO3 BC AO3 OUT DO1 Al2 TYPE LP2 INP Al2 OV LP2 TYPE AO4 INP LP2 OV DO LINEAR STD AO4 TYPE DAT LP2 FB AO4 BC AO4 OUT DO2 5 00 UDC5300 Controller User Manual 7 47 Using a Factory Configuration 7 4 23 Configuration 23 223 Two Independent PID Loops One with Time Proportioned Relay Out and One with Posit
71. Position Low Limit HI LI High Limit Table 11 1 Program Setpoint Profiler Prompts Range Selections Definition XX XXXX Input Decimal Position Move the decimal point to the XXX XXX position to be used in the input value provided to the XXXX XX profiler XXXXX X XXXXXX XX XXXX Output Decimal Position Move the decimal point to the XXX XXX position to be used in all output parameters of the profiler XXXX XX XXXXX X XXXXXX OFF Low Limit and High Limit Specify the limits for the NUMBER profiler s output range SP1 OV OFF Deviation Hold Loop 1 and Deviation Hold Loop 2 Select the parameter typically LPn PV whose value will be Deviation Hold Loop 1 DP L2 Deviation Hold Loop 2 PARM analog NUMBER profiler s output by more than the Deviation Limits see compared to the profiler output value SP1 OV DVPLL and DVPHL in Table 11 2 The set point profiler holds if this source deviates from the Reset Run Input When the profiler is in a HELD ENDed pointed to from 0 to 1 resets the profile to the beginning The transition from 1 to O starts it running again at the beginning or ready state the transition of RRIN or the parameter The value of RR IN is ignored while the profiler is active 5 00 UDC5300 Controller User Manual 11 3 Configuring and Using Setpoint Profiler Table 11 1 Program Setpoint Profiler Prompts Prompt Range Selections Definition Full name
72. REVIEW menu STORAGE NO Storage Set to YES to protect access to any part of data VES storage via online STORAGE menu Does not affect access to online Data Storage Status DS STAT display 5 00 UDC5300 Controller User Manual 9 79 Using Program Mode to Configure Function Blocks and Features 9 14 Setting the Clock This optional real time clock is provided when either the Data Storage feature or the Setpoint Profiling feature is used To ensure that data alarms and events receive the correct time stamp set the clock and calendar The clock uses military time twenty four hour clock To set the date and time select SET CLK from the main Program Menu Set Clock prompts Table 9 37 describes the Set Clock prompts The clock and calendar will be updated when ENTER is pressed in response to the SAVE CHANGES prompt Table 9 37 Set Clock Prompts Prompt Range Selections Definition Full name SET MON range is JAN through Set Month Select the current month Set Month MER SET DAY range is 1 to 31 Set Day Select the current day of the month SET YEAR Set Year Enter the year SET HRS range is 0 to 23 Set Hours Set current hour SET MIN range is 0 to 59 Set Minutes Set current minutes SET FRMAT Set Date Format Select the date format Set Date Format USA USA MMDDYY INTRNL INTRNL DDMMYY ATTENTION Resetting the clock can affect
73. Ratio Position Variable Bias Proportioning Analog Analog Input 2 Slidewire Output 1 Feedback ber 100 1V Configuration 12 112 PID Ratio Control with Position Proportioning Relays Out Controlled PV Output Tracking Value Slidewire Feedback Remote Manual Status Analog Input 1 PID Loop 1 Analog Input 2 0 100 Analog Input 3 0 100 Relay 2 ING _DEC Relay 4 Position Proportioning P 1 1V Relay 1 Discrete Input 1 O Relay 3 Configuration 13 113 Backup to Primary Controller or PLC Position Proportioning Relays Out Analog Input 1 PID 0 100 Loop 1 Relay 1 INC LDEC Relay 2 DIAT Configuration 14 114 PID with Direction Impulse Adjusting Type Relays Out Analog Input 1 PID PV Loop 1 0 100 C Relay 1 On Off Configuration 15 115 Single Loop with ON OFF Relay Figure 5 2 Single Loop Factory Configurations continued UDC5300 Controller User Manual 5 31 Planning Analog Input 2 0 100 Analog Output 1 Analog Input 1 PID tee 0 100 ae al Configuration 16 216 Cascade PID with Current Output Analog Analog Input 1 pier Output 1 PV Loop 1 0 100 ik oils Analog Analog Input 2 Lar Output 2 PV Loop 2 Configuration 17 217 Two Indepe
74. Root Enables disables calculation of square R root of input before value is passed to another function Square Root block YES YES Enables square root calculation NO NO Disables square root calculation CKLO OFF Circuit Low Actual low end value of voltage to be Circuit Low NUMBER used for measurements Appears only if SQRT was set to YES CKHI OFF Circuit High Actual high end value of voltage to be Circuit High NUMBER used for measurements Appears only if SQRT was set to YES CKUN Circuit Electrical Unit Unit of measure in which input ae ical will be expressed Unit is used for CKLO and CKHI Circuit Electrica if SQRT is used as well as for definition of the X Unit coordinates of the custom curve MV Millivolts VOLTS Volts OHMS Ohms value This provides digital filtering LAG to the Lag Time NUMBER measuremeni SONSAN range is 0 to 120 if EXPINP i seconds LAG prompt only appears I is enabled under FEATURES on the Program Mode Menu LAG OFF LAG Time constant applied to the input measurement 9 10 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 4 Custom Al Algorithm Prompts Prompt Range Selections Definition Full Name HOLD OFF Sample Hold When HOLD has a value of 1 entered PARM discrete here or read from the specified parameter the input Sample Hold g value is held at the l
75. SCR ON Inductive YQ RR Load 0 1mf 400V SD Part 023794 Load Power Phase Angle Firing SCR TB4 Parts Table ae Fer c R a S g Motor oa Power Current mfa P t ohms Parti 26 N L1 100mMA 0 01 023474 470 011140 27 L2 N 2 05A 0 02 023098 12 011133 28 10A 0 1 023794 39 011127 S 29 20A 0 3 NotAvail 39 011127 0 22 iia 10 4 50A 1 0 Not Avail 10 011120 30 W a at Ur 1 22 ohm T C MI 32 V S 0 22 mfd CCW A Part 023347 or equivalent Not req d for 1026X drive units Position Proportioning PP Figure 4 1 Noise Suppression For Outputs 5 00 UDC5300 Controller User Manual 4 5 Wiring Signal input and output wiring Terminal configurations are factory assigned according to the circuit cards installed in each individual controller Customer I O terminals are illustrated in Figures 4 4 through 4 7 Note that terminal usage depends on the hardware options selected See model selection guide in Section 2 Make a list of all input and output connections then double check it for accuracy a mistake could be costly and time consuming to correct Wiring diagrams for factory configurations If you ordered the controller with a factory configuration already loaded or if you load one yourself it is essential that the I O wiring be installed correctly for th
76. Specify the source of the input values to be compared comparison Input 1 OPER Input 2 The output CVn OS will be set to ON if the comparison is true Greater Than or Equal To gt Greater Than gt Less Than lt Less Than or Equal To lt Equal To Operator Specify the operator to be used for the Not Equal To On Label and OFFL Off Label See Table 9 14 in the Summary display and by optional data storage feature when the output is ON value 1 and OFF value 0 On Label and Off Label Select the labels to be used 9 64 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 30 CV Compare Prompts Prompt Range Selections Definition Full name CTYP NONE Condition Type Specify the condition type See Table 9 21 for interaction between condition types and Condition Type DELAY i E Aa w yp EXTEND PULSE RT PLS CTIM OFF Condition Time Specify the condition time See Table 9 21 for interaction between condition types and Condition Time NUMBER oe renee ae reer eee HYST OFF Hysteresis Applies to all operators except EQ and NUMBER NEQ If given a value hysteresis determines when Result goes OFF 0 after the comparison becomes false Operator Hysteresis Function GT Result goes OFF when Input 2 Input 1 gt Hyst GTE Result goes OFF when Input 2 Input 1 gt Hyst LT Result goes OFF when Input 1 Input 2 gt
77. The configuration of the CARBON type CV block used in our example is detailed in Table 12 9 Table 12 9 CV2 Configuration for Carbon Potential Calculation CV2 Programming Notes IDPT XXXXX X Set the decimal point to the appropriate position ODPT XXXXX X Set the decimal point to the appropriate position PROB AACO FCC MARTHN Select probe manufacturer or SUPSYS PBIN Alt These assignments match our use of input terminals and the OOOO associated Al function blocks TPIN Al2 TPUN F C K R Specify unit of measure for TPIN Entry should match Al2 range TPLL Specify low temperature limit See Warning on page 12 6 1400 F is recommended CO CN2 OV As described above using a CN as the source of the CO and PFURN CNIOV o FURN values allows you to display and change the values online Specify the percentage of hydrogen in the gas used for carburizing Default is 40 LP block to control enrichment and dilution of carburizing gas The PID loop controls enrichment and dilution of the carburizing gas based on the C value produced by the CARBON type CV block In our example we use a standard splitter with DAT duration adjusting type output The configuration of the LP block is detailed in Table 12 10 12 10 UDC5300 Controller User Manual 5 00 Carbon Potential Option Note that not all internal parameters are listed Configure the tuning parameters a
78. a control room or relatively clean factory environment Do not install it in offices or residential locations The front of the instrument is gasketed and will provide reasonable protection from dust and moisture when properly installed in a panel The keypad display bezel assembly at the front of the unit is a gasketed lift up module providing easy access to the optional data 5 Select an installation location that meets the specifications in Section 2 The controller is storage device 6 If extremely hot or cold objects are near the installation location provide radiant heat shielding for the instrument UDC5300 Controller User Manual 5 00 Unpacking Preparation and Mounting 3 3 Mounting Introduction Figure 3 1 illustrates how the instrument is attached to a panel Provide the panel cutout as shown Note that the panel may be up to in thick ATTENTION The controller is considered rack and panel mounted equipment per the safety standards listed in 2 2 Specifications Conformity with these standards 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 ATTENTION If the controller is used in a manner not specified by Honeywell the protection provided by the equipment may be impaired Procedure To mount the instrument to the panel follow the procedure in Table 3 2 Table 3 2 Panel Mount
79. aar a heen anne a e EN eee ede 11 8 Table 11 4 Procedure for Loading a Profile sensia arnie den eee aser tanaka velcaxeveuateeeindetcetindels 11 9 Table 115 SETPOINT PROM Key MEDU oe ussel ret unre AR eee kones ane saat oan dats 11 10 Table M 6 SEtpomnt Promiler Stats MER ccs eee AA En hd he E ele ass ndde 11 11 Table VIET Chaneine a Secme Time Or Valer orena a aia ihc dn and hata shield 11 11 Table 12 1 Probe Manutactiir ers Specified Ranees sa ie iaedensciaeticinetis ieaassitedies ER 12 3 Table 12 2 Probe Manufacturers Valid Working Ranges seeesescccceeeceecceeeaaeeeeeeeseseeeeeeeeeeeeaaaas 12 3 Table 12 3 CV Carbon Potential Promptsicicecccdacarssinacahecenietacinonesvasehaeuenbienle N 12 4 Table 12 4 AIl Configuration for Oxygen Probe Input cc eeeesssessseeeeeeceeeeeeeaaseeeeesseeeeeeeeeeseeeeeeas 12 8 Table 12 5 AI2 Configuration for Oxygen Probe Temperature cccccccccecceceeeeessseseesseeeeeeeeeeeeeaas 12 8 Table 12 6 CV1 Configuration to Enable Display of Temperature ccccccssssseessseeeeeeeeeeeeeeaaas 12 9 Table t2 7 CNI Contrenratron tor FURN VARER sicsssiesc teal end E 12 9 Table 12 58 CN2 Contictration FOG ON ales eee il ireren ae sb aes ealaddaates 12 10 Table 12 9 CV2 Configuration for Carbon Potential Calculation cccccccccssssseeseseeeeeceeeeeeeeeaas 12 10 Table 12 10 LP1 Configuration for Control of Carburizing Gas ccccccccecececeeeeseeseseeeseeee
80. algorithms require a feedback analog input AUTO permits normal feedback positioning of the drive motor when the feedback input is good and defaults to DIAT operation if the slidewire feedback input fails 9 33 Using Program Mode to Configure Function Blocks and Features Table 9 12 PP Analog Output Prompts Prompt Applies Range Selections Definition Full name To INC PP DOO Increase Output and Decrease Output Specify the discrete outputs used to implement Increase DO PP or DIAT output Output DO Select DOO for None DEC DO3 The input and action of the selected DO function blocks will be unprogrammable under the PRG Decrease DO4 DO ment item Output 9 34 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 5 Programming Discrete Inputs A DI DO card supporting two or three discrete inputs is a controller option Each DI has an associated DI function block The Discrete Input menu item used to configure the DI blocks will appear if a DI DO card is installed Select PRG DI on the Main Program Menu Select a discrete input to program Discrete input prompts Table 9 13 describes the prompts for DI blocks Table 9 13 Discrete Input Prompts Prompt Range Selections Definition Full name ACST Action State Specify whether the input will be normally closed or normally open when ON NORMAL Normal Closed when ON not inverted INVERT Invert Clo
81. algorithms require a feedback analog input The F rd AUTO selection of Auto allows normal PP feedback positioning of a drive motor when the feedback input is good and defaults to DIAT operation if the slidewire feedback input fails Use of Auto requires that the loop type be DIAT The PP algorithm can be used with all PA Select the algorithm type Applies to PP type AO only The PP and Auto other PID loop types MON and MOFF Specify the minimum Applies to DAT type AO only The output will be on or on off times 0 30 off for at least this long even if the input source calls for Min On Time and seconds for the output less time Min Off Time on and off time of the output For example a time of 150 seconds will cause the output to be on for 75 seconds and off for 75 seconds when the input source is at 50 FSV Enter a number Applies to CAT VAT and DAT types of AO only The IMPT 1 to 300 seconds Applies to DAT type AO only Enter the cycle time for failsafe output is the initial output of the analog output on cold start If the Failsafe Value is set to OFF the output will go to 0 on a cold start startup and when a failure occurs 5 00 UDC5300 Controller User Manual 15 13 Using Online Menu Functions 15 5 Reviewing Programming Introduction Use the REVIEW item on the Online menu to examine current programming settings without taking the controller offline The settings cannot be edited in Online mode
82. an Oil Heated Chemical Reaction Chamber In Figure 8 11 the temperature in a chemical reaction chamber is determined by the temperature of the heated oil surrounding it Heating the oil is done by an electric heating element driven by a4 mA to 20 mA controlled SCR and external power source In this application the instrument controls the temperature of the chemical reaction chamber through control of the heat emitted by the jacket tank oil The instrument must provide a single 4 mA to 20 mA control output to govern the voltage switched by the SCR and hence the heat applied to the entire system Temperature is monitored with thermocouples The function block diagram of the required instrument configuration is featured in Figure 8 12 Note that this diagram illustrates the classic cascade arrangement of two control loops that defines the cascade control strategy The first control loop LP1 is designated as the primary UDC5300 Controller User Manual 5 00 Learning to Create Custom Programs 5 00 cascade loop by the notation CAS_P The notation CAS_S indicates LP2 s designation as the secondary cascade loop Note how both control loops are joined together In addition to the back calculated feedback path set up between the two LP2 BC LP1 s output is connected to an input on LP2 that at this time must be introduced Denoted as SP2 this input is LP2 s remote set point input REACTION VESSEL THERMOCOUPLE 4 TO 20 mA
83. an analog output AO block to provide the output signal e ON OFF control would use an AI for the input and a discrete output DO to control the output relay Depending on the type of control additional blocks are required to handle input and output For example e Ratio control requires two analog inputs one for the wild variable and one for the controlled variable e PID control using Duration Adjusting Type DAT output requires an AO block to receive the output from the LP and a DI block to transfer the output from the AO to the relay e PID control with Position Proportional PP output requires two relays so two sets of paired AI and DI blocks are used e PID control with split output uses a calculated value CV block to split the output between two or three analog outputs each with an associated AO block Complex strategies are supported The capabilities of the controller permit many variations on the basic control strategies by allowing both analog and discrete calculated values from CV blocks to be used as the source of the values for the various parameters within the control algorithms Constant CN blocks can be used to provide true constants programmed in the CN block or variable values read by the CN from other blocks to other blocks adding flexibility to the strategies A single parameter can be read by any number of function blocks in the unit 9 12 UC5300 Controller User Manual 5 00 Loop charac
84. analog input has been programmed for a particular input type and or electrical range a specific gain setting is applied to the signal within the controller This gain setting is part of the signal conditioning used to prepare the measurement for the control algorithms There are four gain settings as indicated in the table below Each is expressed in terms of voltage units The gain setting 1s automatically selected by the controller to cover the high and low limits established by the input span configuration The table below indicates the electrical signal span that each gain setting will accommodate UDC5300 Controller User Manual 5 00 Messages When the gain setting is the lowest measurable the highest measurable signal will be signal will be 25 mV 30 mV 30 mV mv O 90 mV 90 mV AM 200 mV 1200 mV BV 300 mV 5200 mV Example An analog input is configured to accept a 1 V to 5 V signal Its gain setting will be 5 V With this setting if the input signal ever falls below 300 mV or goes above 5 2 V and INPUT FAILURE diagnostic message will be displayed Clearing the INPUT FAILURE message To clear the INPUT FAILURE message from the display press the MENU key If you do not press the MENU key the controller will stop showing the message after it has scrolled across the display twice Once the message is no longer displayed it will still be listed in the summary of diagnostics but it will no lo
85. and named DO1 Recall that any analog input control loop analog output or discrete output available may be used Up to 24 discrete outputs DO1 through DO24 are potentially available depending on the instrument s model number From Figure 8 8 the instrument s AI1 function block will essentially process the 4 mA to 20 mA transmitter signal to generate a pH measurement This measurement will be AI1 OV which in turn will be applied to LP1 s process variable input PV Before the 4 mA to 20 mA signal is applied to AI it will be converted to a 1 to 5 Vdc signal with a 250 Q shunt resistor AI will be configured to generate a pH measurement in a range from 0 RANGE LOW 0 to 14 RANGE HIGH 14 in response to a voltage input between 1 CKT LOW 1 and 5 CKT HIGH 5 Vdc The PID algorithm of the control loop function block will adjust the value assumed by LP1 OV between 0 and 100 This 0 to 100 signal will be applied to AOI which will be configured as a DAT type analog output The internal parameter of IMPULSE TIME in AO is the DAT analog output s cycle time or period With a specified impulse time of 150 seconds an arbitrarily picked value the DAT output will be ON for 75 seconds and OFF for 75 seconds when the input from LP1 is set to 50 The ON and OFF times will be determined completely by the output levels called for by LP1 Finally to externalize the ON and OFF output states of AOI to the o
86. aside SES NNE Ree RENSE ES S DER tenance aaah aanneed ERE TERESE ER SEERE PE SEEGER 11 5 11 5 storing and Loading Profes LE VS e Ea ele anale aE 11 8 11 6 USAS epo POTS sashes hatches leas ida sees ao be r be eee arena DA orne 11 10 12 CARBON POTENTIAL OPTION LEDE aiaiai iaiia ed 12 1 12 1 Ea az e 2 Key a eeemmecee tee treme cones E tar errr con er ee nme OnE Seon enero noe 12 1 22 Fonc V6 765 I FU denne ener ricer ron eter E DEERE SET fc aren ve ie PaNrT ec ret vane ne estes nar nner rae reese LER 12 2 DZD PA cHons Per orme doenca a aa a aa SEE 12 2 2A Emme an ZC CUMACY a a a a aaa a EP ESTER RE Noire van aes 12 3 12 3 CARBON Type CV Prompiseisnereie A seats cia ieee rela as as alieb eed seas eatin 12 4 12 4 NPD Gator NOES crnini e a N casa t a db KASSERES 12 6 AKON IN O SEE a rate ecto cesta esas ores eetc ee ac asl ake Actas eet ERE 12 6 1242 Function Block CommouratiOn so le inert eae eles 12 8 124 3 Display Onl CuraulOM sorcen nest iaantteedstieanet xa ane ber ease AE 12 14 13 FINAL PREPARATIONS FOR BRINGING CONTROLLER ONLINE 13 1 13 1 NUT ga 18 HU BIO cesta he ce cepete A E A SE SERNEE SE ERERDEE DRE vaste toes esneauentneuenuee 13 1 13 2 PRE ub NG ga A OOP ARDEN RES RE SE SER JER SESERE PRESSEDE A 13 2 13 3 Comission e ETS asc tu gete teu esearch ea T 13 6 14 USING PRIMARY DISPLAYS TO VIEW PROCESS VALUES AND CHANGE SET POINTS cieren 14 1 14 1 NS TE 0168 cr 81 a B RS EEPE E EE AAE EEE TE EAE ER A E EET
87. assign engineering units to a specific voltage or millivoltage span Square Root Input from a flow transmitter When SQRT is selected square root of input will be calculated Also you will be prompted to assign engineering units to a specific voltage or millivoltage span Engineering units of flow may be used for the span limits of flow inputs Circuit Low and Circuit High Actual low and high end values of voltage to be used for indirect measurements selected for D ID Appears only if INDIRE or SQRT was previously Circuit Electrical Unit Unit of measure in which CKLO and CKHI are expressed Millivolts Volts Ohms LAG Time constant applied to the input measurement value This provides digital filtering LAG to the measurement LAG prompt only appears if EXPINP is enabled under FEATURES on the Program Mode Menu DIRECT INDIRE SQRT CKLO OFF Circuit Low NUMBER CKH Circuit High CKUN Circuit Electrical Unit MV VOLTS OHMS LAG OFF Lag Time NUMBER constant range is 0 to120 seconds HOLD OFF Sample Hold PARM discrete 0 Sample Hold When HOLD has a value of 1 entered here or read from the specified parameter the input value is held at the last value The input value is measured normally when HOLD or the specified parameter has a value of 0 HOLD appears only if EXPINP is enabled under FEATURES on the Program Mode Menu 5 00 UDC5300 Cont
88. be specified using two to twenty points The custom algorithm includes a lag filter and the capability to hold the input value if a discrete parameter goes ON has a value of 1 Input You never have to program the source of an AI block s input because the association between input terminals and an AI block is fixed If you have more than one input be sure to observe this correlation A label on the side of the controller identifies the AI number for each set of input screw terminals Output Any block s output value including the AI output value OV can be used as source of the input to more than one function block simultaneously As our example in Figure 5 1 shows the AI OV is usually read by a loop LP block AI OV is also frequently used as the input to one or more alarm AL blocks Special information If pyrometry is not used at your site you can streamline the list of configurable standard AI types by turning off the display of pyrometer types See 9 12 Diagram Analog Input Al nalog om ae ZE output value gt 5 00 UDC5300 Controller User Manual 5 7 Planning 5 2 4 3 Analog Output Block Use Input Output 5 8 Each analog output AO function block serves one of two purposes e If your strategy uses Current Adjusting Type CAT or Voltage Adjusting Type VAT control output that is if the field device being controlled needs an analog signal then the AO block is the int
89. below setpoint A control deadband is configurable Although it is titled heat cool it can be used for other applications The split output is achieved with a calculated value CV function block programmed to be a standard splitter A DAT Duration Adjusting Type analog output AO function block interfaces between the loop LP block and the discrete output DO block associated with the relay In this application the AO block is not associated with analog output terminals Basic diagram Analog Input 1 PV 0 100 Wiring diagram AO1 7 10 Analog HEAT Pai 1 PID CV9 A C Relay 1 lt Time Prop Alt S IHS OHA OS Ce el Sa E SO O O O77 LIN RET HASS V RE ESS LOAD SO JE V SEN 1o i DO1 QO KR FRE JAR SK ERE ER TO Load Q Q Q Q Power UDC5300 Controller User Manual 5 00 Programming diagram All TYPE 5 00 LINEAR LP1 PV LP1 TYPE CV9 INP Al1 OV SPLIT LP1 OV A Using a Factory Configuration AO1 TYPE AO1 INP CAT CV9 A1 CV9 FBI AO1 BC E CV9 TYPE ORANGE SPLT S AO3 INP AO3OUT gt pot CV9 A2 DO1 4 CV9 FB2 AO3 BC LP1 FB CV9 BC UDC5300 Controller User Manual Using a Factory Configuration 7 4 4 Configuration 04 104 Heat Cool with Current Out for Heat and Positio
90. block 9 73 CTIM CV CMPARE parameter 9 65 CTIM CV LOGIC parameter 9 47 CTLA LP parameter 9 16 CTYP CV CMPARE parameter 9 65 CTYP CV LOGIC parameter 9 46 current output See CAT output cursor use 6 11 CUST INP FEATURES prompt 5 36 9 3 9 77 CV block description 5 10 parameters 9 38 9 66 used to display input value 12 9 D DAT output example 8 7 12 12 programming 9 32 wiring 4 14 data entry 15 11 15 13 data storage 17 1 17 13 database services See DB SRVCE datalink See serial communications date setting 9 80 viewing 15 7 DATSTR FEATURES prompt 9 76 DB SRVCE Maintenance menu item 19 7 DEC AO PP parameter 9 34 DECREMENT key functions 6 16 DEL DIAG SUMMARY prompt 15 7 DELA DI parameter 9 35 DEST CN parameter 9 71 destinations CN block 9 69 9 71 deviation display 14 4 deviation hold 11 2 dewpoint calculation 12 6 DI block description 5 13 parameters 9 35 9 36 DIAG DS STATS prompt 17 11 17 12 DIAG SUM SUMMARY prompt 15 7 diagnostic messages 21 2 diagnostic summary 15 10 15 11 diagnostics See self diagnostics diagramming control strategies 8 2 8 6 DIAT output and loop type selection 9 13 9 14 programming 9 13 9 33 wiring 4 14 D ID AI standard parameter 9 5 DIKY LP parameter 9 25 14 5 DIP switch settings analog inputs 20 2 direction impulse adjusting type output See DIAT output DISC SUM SUMMARY prompt 15 7 discrete inp
91. card Minutes 1 through 5 becomes full See Table 17 6 and Table 17 7 for sample 10 20 30 storage capacities Hours 1 or discrete points to For example if you are storing CVn OV or CVn OS and be stored in the CVn itself gets reprogrammed to type NONE then CVn OV Trend file and CVn OS will no longer be stored but will be replaced by dummy points SY1AX and SY1DX respectively Storage of the other points will continue POINT1 POINT 6 Enter up to 6 analog Beware of programming changes made to collected points 5 00 UDC5300 Controller User Manual 17 5 Storing Data Setting up storage of alarms events and diagnostics Table 17 5 describes the SET AED prompts Table 17 5 SET AED Prompts STRG MOD CONT Continuous CONT Continuous storage becomes active immediately Storage Mode upon initialization BATCH BATCH storage is controlled by discrete parameters defined under the BT SETUP menu Batch data may started and stopped several times in a single file until the card is full Batch start increments a batch number that is stored along with the data The batch number may be used for data retrieval and analysis using SDA software OFF OFF means no AED storage will occur EXT ENAB NONE Use this item to enable disable remote control of data storage through a discrete parameter When this discrete is high logic 1 storage is enabled when low logic 0 storage is disabled This is a separate enable from the STORAGE ENAB
92. change Setpoint 1 PRG DPY5 PVCVL1 display PV and CV4 dewpoint DPY5 CV 4 PRG DPY6 PVCNL1 display PV and display change CN2 CO value DPY6 CN 2 PRG DPY7 PVCNL1 display PV and display change CN1 FURN value DPY7 CN 1 12 14 UDC5300 Controller User Manual 5 00 Final Preparations for Bringing the Controller Online 13 Final Preparations for Bringing Controller Online 13 1 Introduction Overview Once you have programmed the controller you can use the pretune feature to bring your tuning parameters to the best approximation of good operating values This section contains instructions for using the pretune feature as well as some tips for successfully commissioning the controller What s in this section The following topics are covered in this section Topic Page 13 2 Pretuning a Loop 13 2 13 3 Commissioning Hints 13 6 5 00 UDC5300 Controller User Manual 13 1 Final Preparations for Bringing the Controller Online 13 2 Pretuning a Loop Introduction Pretune is a feature that calculates optimum values for a loop s Proportional Band Gain Reset and Rate by analyzing the reaction of the loop to a step change in setpoint or output After these new tuning values have been calculated you have the option of applying installing or not applying them to a preselected set of tuning parameters for the loop You can pretune a loop while another loop is pretuning To pretune a loop select PRE
93. circuit high limit is gt voltage limit of 5200 Change limit to within Zero than or equal to zero 21 6 UDC5300 Controller User Manual 5 00 Messages Impulse Time less than or Equal to 0 Impulse time on a DAT output cannot be less than or equal to zero Incompatible Curve Type Al is custom type thermocouple class reference junction enabled but Y values are not always increasing or not always decreasing Reprogram curve so that for alln Yn gt Yra OF Yn lt Yin Parameters for Incorrect Number of function The function was not programmed with the minimum number of parameters For example the Math CV requires at least 2 inputs to function properly the minimum number of Program function with at least parameters Incorrect Input coordinates The Advanced Splitter CV was programmed with input limits for Output 2 A2 only or for Output 1 amp 3 A1 amp A3 only or for Output 3 A3 only Output 1 only Outputs 1 amp 2 Re program input limits for or Outputs 1 2 amp 3 Coordinates The Advanced Splitter CV was programmed with output limits for Output 2 A2 only or for Output 1 only Outputs 1 amp 2 Incorrect Output or Outputs 1 2 amp 3 Re program output limits for Output 1 amp 3 A1 amp A3 only or for Output 3 A3 only Invalid Type in Point A class of block was detected that is invalid for Spec the product For example y
94. conform to national and local electrical codes 42 0000 UDC5300 Controller User Manul 0 5 00 Wiring Recommended wire In general use stranded copper wire for non thermocouple electrical connections Keep in mind that the maximum load resistance for many process instruments includes the interconnecting wire Observe all local electrical codes when making power connections Unless local electrical codes dictate otherwise the recommended minimum wire size for connections is given in Table 4 1 Table 4 1 Wire Size Recommended Minimums Gage No Description 14 Earth ground wire to supply ground 20 DC current and voltage field wiring 22 DC current and voltage wiring in control room 5 00 UDC5300 Controller User Manual 4 3 Wiring 4 3 Specific Instructions Power connections Connect the instrument to a power mains source of from 85 Vac to 265 Vac 50 Hz or 60 Hz No conversion or special installation is required Figure 4 5 shows power terminals The power supply voltage and frequency must be within the limits stated in the specifications in Section 2 Specify the mains frequency used at your site using the Maintenance menu as described in Section 19 A C Turn power off at mains before installing AC power wiring Protective bonding grounding PROTECTIVE BONDING grounding of this controller and the enclosure in which it is AN installed shall be in accordance with national and local electrical codes The
95. earth ground such as a water pipe with a 2to 1 megohm resistor in series with the ground connection The purpose of the resistor is to current limit an electrostatic discharge and to prevent any shock hazard to the operator The steps indicated above must be followed to prevent damage and or degradation which may be induced by ESD to static sensitive devices ATTENTION After changing an S1 DIP switch s settings make sure you put the controller in online mode for at least several seconds before you calibrate the analog output 5 00 UDC5300 Controller User Manual 20 3 Changing the CAT VAT Switch Settings Procedure 20 4 The procedure for accessing the DIP switches is provided in Table 20 2 Table 20 2 Procedure for Accessing the DIP Switches Turn off power to the controller More than one switch may be required to remove power With the power off access the instrument assembly e Open the front of the controller by pressing the button under the bezel to release the latch and then pulling the bezel forward and up The bezel is mounted on bails If you press the bottom of the bezel toward the back of the instrument to compress the gasket slightly the latch will open easily e When the bezel is lifted out of the way a plate is uncovered A latch on either side of the label on this plate holds the instrument assembly in the case e To release these latches insert a screwdriver tip next to the lever on the right
96. function block itself It is not always possible or even practical to draw every internal parameter that a function block has or might need Therefore as a rule of thumb for starting out you should first think of internal parameters as simple labels that further define and clarify the internal operation of the function block With this rule of thumb in mind internal parameters become items that are hopefully intuitively obvious At this point what may or may not be an intuitively obvious internal parameter will depend on your level of process control expertise For the function block diagram built up so far internal parameters that can be presumed from the control strategy of Figure 8 1 are indicated in Figure 8 4 Here the AIl function block has been labeled to show that its INPUT TYPE will be a Type J thermocouple with a measurement range between 0 RANGE LOW and 1000 F RANGE HIGH The label STANDARD has been used to indicate the type of control loop LP1 will be along with the notation SP 500 to show that the loop s set point will be 500 F The loop tuning constants of GAIN RESET and RATE have been initially indicated as 10 1 repeat minute and 0 minutes respectively As far as the AOI function block is concerned its input range has been defined between 0 IN LOW LIMIT and 100 IN HIGH LIMIT in anticipation of using LP1 s output to drive the 4 mA to 20 mA signal it will generate Note how AO1 s output
97. is set to OFF the entire memory card is allocated for storage of trend data Table 17 6 shows the trend storage capacity in hours for the combinations of a b and c when SET AED STRG MOD 1s set to CONT or BATCH Table 17 7 shows the trend storage capacity in hours for the combinations of a b and c when SET AED STRG MOD 1s set to OFF 5 00 UDC5300 Controller User Manual 17 7 Storing Data Table 17 6 Memory Card Capacities for Trend Data When AED Storage is Enabled 256K card Sample rate in seconds 512K card Sample rate in seconds 1 Meg card Sample rate in seconds 17 8 UDC5300 Controller User Manual 5 00 Storing Data Table 17 7 Memory Card Capacities for Trend Data When AED Storage is Disabled 256K card Sample rate in seconds 1 4 94 49 40 98 80 148 20 296 40 2 3 43 34 31 68 61 102 92 205 83 3 2 61 26 07 52 14 78 22 156 43 4 2 06 20 58 41 17 61 75 123 50 5 1 78 17 84 35 68 53 52 107 03 6 1 51 15 06 30 13 45 19 90 38 Sample rate in seconds 512K card 1 10 02 100 20 200 40 300 60 601 20 2 6 96 69 58 139 17 208 75 417 50 3 5 29 52 88 105 77 158 65 317 30 4 4 18 41 75 83 50 125 25 250 50 5 3 62 36 18 72 37 108 55 217 10 6 3 06 30 59 61 17 91 76 183 52 Sample rate in seconds 1 Meg card ___Sampieratein seconds
98. key 11 10 events storage 17 2 EXPINP FEATURES prompt 5 36 9 76 EXT ENAB SET AED prompt 17 6 EXT ENAB SET TRND prompt 17 4 EXT ENAB STORAGE prompt 17 11 F factory configurations detailed descriptions 7 8 7 60 loading 7 2 overview 5 23 5 36 tailoring to application 7 3 7 6 FAIL AI standard parameter 9 6 failsafe value 9 30 9 32 15 13 19 8 FB CV MATH parameter 9 44 FB LP parameter 9 23 FB1 CV SPLT A parameter 9 62 FB1 CV SPLT S parameter 9 60 FB2 CV SPLT A parameter 9 62 FB2 CV SPLT S parameter 9 60 FB3 CV SPLT A parameter 9 62 features enabling 9 76 9 77 feedback See loops feedback requirements FFGN LP parameter 9 23 15 6 FFIN LP parameter 9 23 field replaceable parts 22 1 Index FILENAME accessed with SETPOINT PRGM key 11 10 FMT MCRD STORAGE prompt 17 3 FORCE DATA ENT prompt 15 11 FORCE FEATURES prompt 9 76 15 11 freeform math equation 9 43 FRM CHNL COPY BLK prompt 9 73 FSAF AO CAT VAT parameter 9 30 FSAF AO DAT parameter 9 31 FSV AO CAT VAT parameter 9 30 FSV AO DAT parameter 9 32 FSV SET AO prompt 15 13 function blocks definition 1 9 5 2 diagramming 8 2 8 6 learning to use 8 2 8 14 output codes 5 21 quantity available 1 3 5 5 FURN CV CARBON parameter 12 5 Furnace Control Corp 12 3 12 4 G gain adjusting on analog input 15 12 GNI LP parameter 9 17 15 4 GN2 LP parameter 9 19 1
99. locks The controller can be programmed to require entry of a password to perform some functions and to change some values One of the items that can be password protected is changing from Online mode to Program or Maintenance mode You will know security has been enabled and that a password is required if when you try to do something you are presented with a display that says x000 SEC LOCK Use the procedure in Table 6 1 to enter the appropriate password The operator password is expected when this display results from trying to change a value using Online mode displays The master password which can be different from the operator password is needed to change modes clear the memory or alter security programming Security is not enabled on out of the box controllers 5 00 UDC5300 Controller User Manual 6 9 Modes Menus Prompts and Keypad Basics 6 3 2 Using the Menus 6 3 2 1 Selecting an Instance of a Function Block Type or Other Item for Configuration Program mode The controller can contain more than one instance of a function block of a particular type Therefore after a function block type has been selected for edit the next step is to specify which of the blocks of that type you want to program For example the controller can support two loops Therefore when you select PRG LP program loop by pressing ENTER the prompt will change to PRG LP1 If you want to configure loop 1 press ENTER
100. may be accessible Failure to comply with these instructions could result in death or serious injury Protective earth terminal Provided for connection of the protective earth green or green yellow supply system conductor Sensing and Control Honeywell 11 West Spring Street Freeport Illinois 61032 ii UDC5300 Controller User Manual 5 00 About This Document Abstract This manual contains instructions for installation and operation of the UDC5300 Controller Contacts World Wide Web The following lists Honeywell s World Wide Web sites that will be of interest to our customers Honeywell Organization WWW Address URL Corporate http www honeywell com Sensing and Control http www honeywell com sensing International http www honeywell com Business global asp Telephone Contact us by telephone at the numbers listed below Organization Phone Number United States and Canada Honeywell 1 800 423 9883 Tech Support 1 888 423 9883 Q amp A Faxback TACFACS 1 800 525 7439 Service Asia Pacific Honeywell Asia Pacific 852 2829 8298 Hong Kong Europe Honeywell PACE Brussels Belgium 82 2 728 2111 Latin America Honeywell Sunrise Florida U S A 854 845 2600 5 00 UDC5300 Controller User Manual CE CONFORMITY This product is in conformance with the protection requirements of the following European Council Directives 89 336 EEC the Electromagnetic Compatibility Directive and 73 23 EEC the Low Voltage
101. number and version of installed firmware UDC5300 Controller User Manual 15 7 Using Online Menu Functions 15 3 1 Alarms Introduction Up to four process alarms AL1 through AL4 are configured as part of the controller programming procedure see Section 9 Alarm types An alarm can be assigned to any analog data point Analog Input Analog Output or Calculated Value and can be one of the types in Table 15 4 Table 15 4 Alarm Types Alarm type Meaning HIGH Alarm when input value gt alarm setpoint value LOW Alarm when input value lt alarm setpoint value DEV Alarm when input value deviates above or below me compare point value by an amount gt alarm setpoint Deviation value HDEV Alarm when input value deviates above compare point value by an amount gt alarm setpoint value LDEV Alarm when input value deviates below compare point value by an amount gt alarm setpoint value HRATE Alarm when input value increases at rate gt alarm setpoint value in units per minute Negative rate setpoints are processed as positive values May take up to 30 seconds to activate High Rate setpoints are processed as positive values May take up to 30 seconds to activate LRATE Alarm when input value decreases at rate gt alarm setpoint value in units per minute Negative rate Low Rate zi ig Alarm actions The following things happen during an alarm e The appropriate alarm number indicator lights
102. only PV and Calculated Value selected during PRG CV DPYS programming PV Allows online changes to constant selected during PRG CN DPYS programming while viewing read only PV SP1 If the working setpoint is clamped at the setpoint high or low limit for the loop this can be different than the value of the PV Allows online changes to SP1 while viewing read only PV working setpoint Setpoint Select the current loop PV Use ENTER A or VW to toggle between SP1 and SP2 for 14 4 UDC5300 Controller User Manual 5 00 Using Primary Displays to View Process Values and Change Setpoints 14 3 How to Use Primary Displays Introduction When a primary display is shown the keypad can be used to e select auto or manual mode for the loop e change loop output e change the setpoint value e change a constant value e change ratio value of a ratio control loop e control the status of a setpoint profiler see Section 11 Instructions for performing these functions are described below ATTENTION These functions all apply to the currently selected loop which is designated on the display Instructions for changing tuning the selected loop s parameters are provided in Section 15 Selecting auto or manual mode This function can be performed on all primary displays Pressing MANUAL AUTO toggles the loop between auto and manual modes In auto the controller s output is calculated by the control algorithm In local man
103. or Loop 2 appear in that position in the sequence The display you assign to PRG DPY 1 will appear when the DISPLAY key is pressed once the display assigned to PRG DPY 2 will appear when the DISPLAY key is pressed a second time etc Program Display 1 PRG DPY1 Note n 1 or 2 Program Display 1 through Program Display 10 For through setpoint If the working setpoint is not clamped at the setpoint low or high limit changing the working setpoint will also change SP1 or SP2 whichever is being used assuming that SP2 is not originating from the setpoint profiler Program PRG DPY10 PVSPLn PV and working SP Allows online changes to working Display 10 PV and loop output Allows online changes to loop output only PVS1Ln PV and SP1 Allows online changes to SP1 If the working setpoint is clamped at the setpoint low or high limit this display is necessary to change Setpoint 1 PV and Setpoint Select Allows toggling between SP1 and SP2 for the loop None When the DISPLAY key is pressed the next display in the sequence will appear 9 74 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 34 Program Primary Display Prompts DPYx CV Display x Calculated Value range is 1 to 16 Display x Calculated Value If you select a display containing a CV this prompt appears Enter the number 1 to16 of the CV whose
104. precision variable resistor Procedure The procedure for calibrating inputs used for RTD inputs is provided in Table 19 2 Table 19 2 Analog Input Calibration Procedure for RTD Inputs 1 Disconnect power to all terminals More than one switch may be required to remove power 2 With the power off connect the precision variable resistor to the terminals of the input to be calibrated Calibrating one analog input results in all in analog inputs being calibrated 3 Power up the unit 4 Go into Maintenance mode and scroll to the CALIB Al prompt Press ENTER 5 Select the input to be calibrated and press ENTER CAL 25MV will be displayed 6 scroll down to the prompt CAL 100 message CALIB IN PROG will be displayed while the RTD low range calibration is accomplished If the calibration is successful the Maintenance menu item CALnn will be displayed If the calibration fails because the required adjustment exceeds the acceptable range the message CALIB FAIL will be displayed 7 Set the resistor to 100 ohms then press ENTER on the controller The 9 When calibration of the input is complete power down the controller before disconnecting the test leads Restore the field wiring to the calibrated input with all power removed 19 4 UDC5300 Controller User Manual 5 00 Using Maintenance Mode 19 3 Calibrating Analog Outputs Introduction Periodic calibration of the outputs is
105. range has been defined through use of the notation OUT LOW LIMIT 4 and OUT HIGH LIMIT 20 TYPE J All OV THERMOCOUPLE Ree ih INPUT TYPE J RANGE LOW RANGE HIGH 1000 TYPE STANDARD OUTPUT TYPE CAT SP1 500 IN LOW LIMIT 0 GAIN 10 IN HIGH LIMIT 100 RESET 1 OUT LOW LIMIT 4 RATE 0 OUT HIGH LIMIT 20 Figure 8 4 Labels for Internal Function Block Parameters 8 4 UDC5300 Controller User Manual 5 00 Learning to Create Custom Programs Note that the internal parameters that we have specified in the function block diagram built up so far are based largely on what can be inferred from the elements of the control configuration depicted in Figure 8 1 These internal parameters will relate directly to settings found in instrument programming menus that exist for each particular function block As your experience and familiarity with programming the instrument increases you will become more familiar with some of the less intuitive parameters and you will include these in your diagrams 5 Connect the blocks 5 00 The next step is to connect the function blocks in the diagram Refer to Figure 8 5 The interconnection lines drawn depict the flow of information between function blocks and represent how the blocks work together to support the complete control strategy As shown the furnace zone temperature measurement that AI1 generates will essentially be used as the process variable of the LP1 control l
106. recommended to ensure conformity to the specifications Except in the case of Position Proportioning output see Section 10 calibration of outputs in new controllers is not necessary however field calibration may optimize accuracy if proper eqiupment is used WARNING This procedure should be performed by qualified personnel only Disconnect power to all terminals before connecting or disconnecting calibration leads A potentially lethal voltage is present on the mains terminals and may be present on other terminals More than one switch may be required to disconnect power Select CALIB AO from the Maintenance Menu Select an AI to calibrate Materials required To calibrate the output you will need e ascrewdriver to fit the terminal blocks on the rear of the controller e for VAT outputs a precision voltmeter e for CAT outputs a precision milliammeter or a precision resistor and voltmeter ATTENTION If you are calibrating an analog output that was changed from a CAT to VAT or vice versa as described in Section 20 put the controller online for several seconds before calibrating Procedure The procedure for calibrating outputs in Table 19 3 5 00 UDC5300 Controller User Manual 19 5 Using Maintenance Mode 19 6 Table 19 3 Analog Output Calibration Procedure Disconnect power to all terminals More than one switch may be required to remove power With the power off connect the meter to the terminals of the outpu
107. represents 0 1 for a total of 1 of range 14 2 UDC5300 Controller User Manual 5 00 5 00 Using Primary Displays to View Process Values and Change Setpoints Upper Display six characters Value of selection indicated Lower Display eight characters Value as setpoint or output Degrees being used Controller mode Fahrenheit or Centigrade Manual or Automatic Active Loop 1 or 2 12 FC MAN Alarm condition ALM PEEP exists 5300 Bargraph Setpoint shows 12 SP 5300 deviation of process H variable i a a 4 setpoint a En ml 2 lt Program status Active setpoint 1 or 2 Keys 24207 o Accesses up to 10 on line displays DISPLAY o Changes controller to on line mode MANUAL o Toggles loop between automatic and manual modes or between AUTO remote manual and manual modes when remote manual is ON o Moves cursor up a menu or list of choices o Increases the setpoint output or configuration values displayed o Accesses on line mode menu o Moves cursor to first item on menu o Backs cursor out of a menu to next higher menu level o Exits menu without saving changes if pressed when prompted to save changes o Accesses setpoint profile displays o Selects the digit to be changed o Moves cursor down a menu or list of choices o Decreases the setpoint output or configuration values displayed o Selects displayed menu item o Enters a changed value or parameter ENTER o S
108. side and gently pry the lever to the left while pulling gently on the right side of the bail linkage see Figure 20 1 Repeat on the left latch then using the bail as a handle gently slide the entire card cage assembly forward end of the card cage to clear the stop then the entire assembly can be The assembly will strike a stop when it is almost all the way out Lift the back removed There are no cables to be disconnected S1 DIP switchbank for AO1 See Figure 20 2 for switch locations lf the controller supports optional AO2 the circuit card in slot 3 counting from the right when facing the controller contains the S1 DIP switch for AO 2 Not all models contain this card Some contain a 2DI 1DO card in slot 3 The card in Slot 1 on the right side when facing the controller contains the The ON position is toward the top edge of the card After setting the switches put the rear of the card cage assembly into the case connectors When the assembly is correctly positioned the two latches will Press the instrument assembly back to fully engage the rear card edge Snap into place Pull on the bail to verify that the assembly is fully seated and firmly latched then swing the bezel down into position Engage the top edge of the bezel first then swing in the bottom and press in until the button latch snaps into place Do not power up the unit until the instrument assembly has been replaced and the assembly latches are fi
109. signal specifications switch characteristics for output circuit card modules CAUTION Safety isolation exceeding the safe working level of 30 V RMS 42 4V peak is not provided between discrete outputs If the working voltage of any discrete output exceeds this level use suitable wire gauge and insulation on all discrete outputs and use proper safety precautions when handling all discrete output wiring Discrete Inputs Connect as required Output Device OA a Nest Voltage Source ieee On Off switch Y for removing power from output devices Voltage ES Source Koy Output Device Discrete Outputs Figure 4 7 Discrete I O Connections We recommend you provide the ac or dc voltage supply with an on off switch in the circuit supplying power to the field output devices Figure 4 7 This will enable removal of output power while the Controller and input devices remain operational during troubleshooting 412 00 00 UDC5300 Controller User Mnual 0 5 00 Wiring Discrete input signal connections See the label on the side of the controller to determine card types Connect discrete switch type inputs to the terminals for discrete inputs in card slot 3 Figure 4 7 Connect input switches and power commons as shown in Figure 4 7 Analog output connections See the terminal label on the side of the controller for analog output card terminal
110. slew limits can be programmed with numerical values only However if such a parameter is programmed to be the destination of a CN block then at runtime the CN block overwrites that numerical value with a live value variable provided by the CN block s input For example suppose LP1 s Gain is programmed as the number 5 and CN1 s Input is CV2 OV the output of Calculated Value 2 By selecting CN1 s Destination to be LPIGN LP1 s Gain will be continuously updated by the live value provided by CV2 OV 5 00 UDC5300 Controller User Manual 9 71 Using Program Mode to Configure Function Blocks and Features 9 72 ATTENTION Always be certain that the destination is compatible with its associated loop or analog output A mismatched destination can affect your output and can be difficult to diagnose Examples If destination is AO1 IT impulse time be sure that AO1 is programmed as a DAT If destination is LP2 IS be sure that Loop2 is a type that has increasing slew limit on its menu ATTENTION e f you remove AOn HS or AOn LS from the destination you must perform these additional steps 1 Access AOn s program menu Change the decimal point position then save the change 2 Re access AOn s program menu Change the decimal point position back to its previous position then save the change e f the destination is a loop parameter it cannot be tuned online in the TUNE LOOP menu e f you reprogram destination to anot
111. symbols if LBAD YES Auto amp SP2 SP2 Failure Working SP SP1 SP2 Select SP1 then SP2 Manual amp SP2 SP2 Failure Working SP SP1 SP2 Select SP1 then SP2 Auto amp SP2 SP2 amp PV Failure Working SP SP1 SP2 Select SP1 then SP2 MAN Select Manual then Mode Suspend Auto PV value Auto Output Failsafe PV value Mode Manual Manual amp SP2 SP2 amp PV Failure Working SP SP1 SP2 Select SP1 then SP2 Output Last value Auto amp SP1 SP2 PV Failure or Mode Suspend Auto MAN Select Manual then RMAN Failure or i Auto OTRK Failure or Output Failsafe FFIN Failure Manual amp SP1 SP2 PV Failure Mode Manual PV value None required Output Last Value Auto amp SP1 SP2 see below Mode Suspend Auto MAN None required Output Back Calc Value Auto amp SP1 SP2 Force Remote Mode Suspend Auto A None required Manual Output Tracking value Due to the abnormal condition the loop cannot be in Auto and therefore is in a temporary mode which forces the output as indicated Status from a downstream function block indicates that there is no path to final output element For example the secondary control loop of cascade configuration was changed to manual mode 5 00 UDC5300 Controller User Manual 21 5 Messages 21 4 Error Messages Introduction Sometimes errors occur while you are programming or operating your controller In most cases the controller
112. the positioner s slidewire is received at AI2 The feedback is powered by a constant 1 V from the terminals associated with AOI and its VAT voltage adjusting type AO function block having an output range from 0 to 5 Because the input to the AO is 20 from a constant CN block a steady 1 V out is achieved 20 of the 5 V range Basic diagram 7 22 HEAT Relay 1 ag Time Prop Analog Input 1 0 100 Ter Pane COOL A E DEC Relay 4 Position Slidewire Analog Input 2 Proportioning Feed back 0 100 Analog Output 1 1 V Power to Slidewire Feedback UDC5300 Controller User Manual 5 00 Using a Factory Configuration Wiring diagram Actuator AH Voltage roe on OQ Or S On OT SUCRE SIS S sE ES OQ EEES OQ EE OQ ESS J5 DO4 INC Al2 DEC Programming diagram AO3 TYPE DAT AO3 INP AO3 OUT CV9 A1 DO1 Q BE v9 FB1 AO3 BC 11 TYPE LP1 PV LP1 TYPE CV9 INP CV9 TYPE DO3 LINEAR Al1 OV SPLIT LP1 OV SPLT_S AO4 INP A CV9 A2 4 CV9 FB2 a 204 AOK DS AO4 TYPE PP LP1 FB CV9 BC AO4 PA PP AO4 INC DOS Al2 TYPE AO4 SLWR Al2 OV AO4 DEC DO4 LINEAR CN9 IN AO1 INP
113. the timer is actively counting or while reset RST is ON 1 and OFF 0 while the timer has timed out to zero When RST switches ON 1 the timer resets to the preset value an ON 1 to OFF O transition starts the timer Internal timer prompts Table 9 24 describes the Interval Timer prompts Table 9 24 CV Interval Timer Prompts Input Decimal Position Move the decimal point to the position used by the inputs to the CV block the position to be used in the output value provided by Output Decimal Position Move the decimal point to the CV block Output Engineering Units Specify the unit of measure Fahrenheit or Celsius for the output Preset Output Value Timer counts to zero from this number of minutes Reset Specify the discrete or enter a value directly here to control the operation of the timer Prompt Range Selections Full name IDPT XX XXXX XXX XXX Input Decimal XXXX XX Position XXXXX X XXXXXX ODPT XX XXXX XXX XXX Output Decimal XXXX XX Position XXXXX X XXXXXX OTEU OFF Output F Engineering Units C PSET OFF Preset Output NUMBER KEE PARM analog RST OFF Reset 1 0 PARM discrete OVLL OFF Output Low Limit NUMBER OVHL Output High Limit Output Low Limit and Output High Limit Specify the output range value will flash to alert the operator of an unusual If the output is outside the range the displayed condition The output will not be clamped 9 54 UC
114. to 28 To make the correlation simply drop the first digit from the model number designation How to load 7 2 Change to Program mode and select FACT CFG then select one of the configurations and press ENTER The configuration will be loaded A message will advise you when the load is completed If the message is LOADED W ith ERRORS press MENU to view the first error then use the INCREMENT A and DECREMENT keys to view any additional errors ATTENTION Loading a factory configuration only alters the values of parameters actually used by that configuration To avoid unpredictable results clear the old configuration from the controller s memory before loading a factory configuration Instructions for clearing the memory using the Database Services item from the Maintenance menu are provided in Section 19 If desired you can first save the previous configuration on an optional PCMCIA memory card as described in Section 16 UDC5300 Controller User Manual 5 00 Using a Factory Configuration 7 3 Tailoring a Factory Configuration to Your Application Overview 5 00 Programming tasks following the loading of a factory configuration fall into two categories NECESSARY CONFIGURATION After loading the configuration you must assign site specific values to function block parameters such as ranges and tuning parameters Each parameter for each function block type is described in detail in Section 9 In a
115. to provide 100 to 100 output to drive two control outputs for heat cool or other dual energy processes e Ratio providing ratio adjustment for the loop remote setpoint and a manual bias input value e Cascade Primary with engineering unit scaling of the control output interlocking with the Cascade Secondary loop to prevent windup and provide bumpless recovery from manual override actions or other process interruptions e Cascade Secondary which accepts a remote setpoint from the Cascade Primary and initiates loop tracking during abnormal conditions e DIAT Duration Impulse Adjusting Type to increase and decrease output to a motor actuator without a feedback slidewire output percentage disabled e ON OFF to provide an ON or OFF output signal to a discrete output relay based on the deviation of the process variable from setpoint While the input to the loop is usually the output value OV of an analog input AO block receiving a field signal the loop s input parameter PV can be programmed to read its value from other analog input parameters such as the output value OV of a peak picking calculated value CV block A number of analog outputs are provided by the LP block In addition to the OV calculated by the control algorithm the PV input value can be read as an output as can the deviation value DV which is useful for alarming Setpoint analog values as well as status discretes are also available See Table 5 3 for a compl
116. value or OFF at the time of configuration The value may be altered online for final loop tuning UDC5300 Controller User Manual 9 19 Using Program Mode to Configure Function Blocks and Features Prompt Full name Manual Reset Approach High Setpoint Tracking 9 20 Applies To Table 9 8 Loop Prompt Descriptions NUMBER range is 100 to 100 NUMBER range is 0 1 to 100 NUMBER range is 0 1 to 100 UC5300 Controller User Manual Manual Reset This feature functions only when OFF is entered for RST1 and RST2 Enter a value equal to the desired loop output when the process variable is at setpoint This allows correction of output to account for load changes to bring the process variable up to setpoint The controller output is the computed output value plus the value of MRST Note If both reset and manual reset are set to OFF the loop output will be zero at setpoint Approach High This function affects the process variable approach to setpoint when the process variable value is less than the setpoint value The value entered is the percent of span deviation from setpoint at which a recalculation of the loop integral value will occur Enter a starting value equal to the proportional band value if Gain is used enter value 1 gain value x 100 or OFF at initial configuration The value may be altered online for final loop tuning This function is useful for batch startup from a col
117. want to enter a number press ENTER when the word NUMBER is on display then follow the procedure in Table 6 1 6 12 UDC5300 Controller User Manual 5 00 Modes Menus Prompts and Keypad Basics Table 6 1 Procedure for Entering a Number 1 When the controller is ready to accept a numerical value the upper display will show the current value of the parameter with zeros preceding it if the value has fewer digits than the display supports When appropriate the string of zeros includes a decimal point Note that the location of the decimal point is usually configurable using a different parameter The right most digit least significant digit will be flashing This indicates that the digit is selected for editing 2 To change a number press the INCREMENT A or DECREMENT VW key The display will cycle through the numbers 0 through 9 3 When the desired value is displayed for the least significant digit use the LEFT lt key to select a different digit for edit Use the INCREMENT A and DECREMENT VW keys to change each digit to the desired value 4 When the number has been edited to the desired value press ENTER to move the cursor back to the prompt Specifying a parameter 5 00 Note that sometimes the valid responses to a prompt include entering a number specifying a parameter in another function block or selecting OFF In this case use the INCREMENT A and DECREMENT YF keys to display your choice
118. 00 Controller User Manual 1 9 Introduction 1 4 Overview of Function Block Programming Concepts 1 4 1 What a Function Block Is Definition A function block is a software object that performs a piece of a control strategy such as processing an analog input or calculating a value A function block can be thought of as a black box that takes data in one end does something to the data inside the box and at the other end makes the data available to other function blocks Internal parameters influence operation How a function block does its job depends on the values programmed for the block s internal parameters For example a loop function block has a parameter that determines the type of algorithm used by the loop 1 4 2 How Function Blocks Work Together Data flow depends on programming Values flow between the function blocks based on the programming of the function blocks With the exception of the system function block every function block type has at least one input parameter and at least one output parameter Input parameters are used to specify where a function block reads its incoming data Although an input can be configured to be a number usually the source of the input is another block s output For example the input process variable of a loop block would be the output value from an analog input block This same output value could also be the input for an alarm block Feedback essential to successful op
119. 01 to 99 When the number you want is displayed press ENTER This initiates the storing operation display reads STORE COMPLETE you can press MENU to exit the function Remove and label the card or go on to Step 7 to store the 6 During the storing operation the display will read FILE STORING When the calibration 7 To store the calibration also press MENU until STORE CFG gt MOD is again displayed then press V STORE CAL gt MOD will be displayed 8 Press ENTER to select this function and the display will change to STORE CALIB 01 9 Repeat Steps 3 through 6 to save the calibration to file 10 Press MENU to exit the function 11 Remove and label the card UDC5300 Controller User Manual 5 00 Storing and Loading Configuration and Calibration 16 3 2 Loading from Card Procedure 5 00 The procedure for loading configuration and or calibration from a memory card to the controller is in Table 16 3 Table 16 3 Procedure for Loading Configuration and or Calibration 1 Clear the old configuration and or calibration from the controllers memory using the CLR CFG CLR CAL or CLR ALL items from DB SRVCE database services in Maintenance mode as described in Section 19 2 Once the memory Is clear put the card containing the configuration to be loaded into the controller 3 Go to CFG FILE in the Program mode menu and press ENTER The
120. 1 The following things happen when a self test is failed e A diagnostic message is displayed e The most recent diagnostic appears at the top of the Diagnostic Summary The ten most recent diagnostics can be viewed here As new diagnostics occur the oldest of the ten 1s removed from the list e If so configured the diagnostic is stored in Data Storage see Section 17 Viewing the ten most recent diagnostic messages Instructions for viewing the ten most recent diagnostic messages are in Table 15 6 Table 15 6 How To View Diagnostic Messages 2 Scroll down to DIAG SUM and press ENTER The most recent diagnostic message or a message that there are no diagnostic failures will be displayed Clearing the Diagnostic Summary A diagnostic message 1s not automatically cleared from the summary when the error has been found and corrected Instructions for clearing all diagnostic messages from the summary are in Table 15 7 Table 15 7 How To Clear Diagnostic Messages 2 Scroll down to DEL DIAG and press ENTER All diagnostics will be deleted from the summary Note that offline tests of the keypad display memory etc can be initiated by the operator in Maintenance mode as described in Section 18 15 10 UDC5300 Controller User Manual 5 00 15 4 Data Entry Using Online Menu Functions You may change the following items online using the DATA ENT item on the Online menu e alarm setpoints an alarm ca
121. 4 00 00 for example Prompts Table 9 25 describes the Periodic Timer prompts Table 9 25 CV Periodic Timer Prompts Prompt Range Selections Definition Full name ONL See Table 9 14 On Label and Off Label Select the labels to be used On Label inthe Summary display and by optional data storage On Label feature when the output is ON value 1 and OFF and value 0 OFFL Off Label TIMR Set Up Timer Pressing ENTER when this prompt is on display takes you into a sub menu of prompts Set Up Timer shown in Table 9 26 Use these prompts to set up the timer 9 56 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 26 CV Periodic Timer Set Up Timer Prompts Prompt Range Selections Definition Full name PHSE Phase Specify the timer phase Phase NONE None Discrete switches ON at end of each period MNTHLY Monthly Each month discrete switches ON at start day and time WEEKLY Weekly Each week discrete switches ON at start day and time DAILY Daily Discrete switches ON at start time then after each period PHRS range is 0 to 23 hours Period Hours This prompt is displayed if PHSE Period H DAILY or NONE Specify the number of hours in the Period Hours period PMIN range is 0 to 59 minutes Period Minutes This prompt is displayed if PHSE DAILY or NONE Specify the number of minutes in Period Minutes the period PSEC range is 0 t
122. 47 contains the needed resistor and capacitors Diagram Figure 10 2 shows the wiring necessary to implement our example factory configuration 11 111 WARNING The diagram in this section is intended to supplement not replace the instructions in Section 4 Wiring Be sure to read and understand Section 4 before attempting to connect power or signal wires Turn power off at mains before installing AC power wiring All oe aor tT ER LOT ILS D i S S S L1 Actuator Dim m An Voltage E aa Sis A Q IQ OS DEL S PONS DO2 y INC Al2 3 DEC Figure 10 2 Wiring for Factory Configuration 11 Shown in Figure 10 1 10 6 UDC5300 Controller User Manual 5 00 Position Proportioning Output Setup and Calibration 10 4 Calibrating Introduction Once the controller has been programmed and wired correctly to support PP output the controller s position output must be calibrated with the device to be controlled ATTENTION Calibrating the PP output requires stroking the drive motor over 100 of its travel This procedure is recommended as an offline procedure only If the calibration procedure is bypassed PP operation may proceed but full scale travel of the actuator may not be achieved during online operation Procedure Instructions for calibrating the PP output are in Table 10 2 Ta
123. 5 4 GNPB LP parameter 9 17 H hardening carburized parts 12 1 HILI SP block parameter 11 3 HOLD AI custom parameter 9 11 HOLD AI standard parameter 9 5 HOLD setpoint profiler STATUS prompt 11 11 HOLD SP block parameter 11 4 holding a setpoint profile 11 12 HYDR CV CARBON parameter 12 6 HYST AL parameter 9 68 HYST CV CMPARE parameter 9 65 HYST LP parameter 9 22 15 5 I IACT LP parameter 9 26 IDENT Pretune prompt 13 3 IDPT AI custom parameter 9 9 IDPT AL parameter 9 68 IDPT AO CAT VAT parameter 9 29 IDPT AO DAT parameter 9 31 IDPT AO PP parameter 9 33 IDPT CN parameter 9 70 IDPT CV CARBON parameter 12 4 IDPT CV CMPARE parameter 9 64 IDPT CV ITIMER parameter 9 54 IDPT CV MATH parameter 9 43 IDPT CV SPLT A parameter 9 61 IDPT CV SPLT S parameter 9 59 IDPT CV SSEL parameter 9 41 IDPT CV TOTL parameter 9 51 5 00 UDC5300 Controller User Manual Index 3 Index IDPT LP parameter 9 16 IDPT SP block parameter 11 3 IH1 CV SPLT A parameter 9 62 IH2 CV SPLT A parameter 9 62 IH3 CV SPLT A parameter 9 63 IL1 CV SPLT A parameter 9 62 IL2 CV SPLT A parameter 9 62 IL3 CV SPLT A parameter 9 63 IMPT AO DAT parameter 9 32 IMPT SET AO prompt 15 13 IN CN parameter 9 70 INC AO PP parameter 9 34 INCREMENT key functions 6 15 INEU CN parameter 9 70 INEU LP parameter 9 21 INHL AO CAT VAT parameter 9
124. 5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 24 CV Interval Timer Prompts Prompt Range Selections Definition Full name ONL See Table 9 14 On Label and Off Label Select the labels to be used L i in the Summary display and by optional data storage On Label feature when the output is ON value 1 and OFF and value 0 OFFL Off Label 5 00 UDC5300 Controller User Manual 9 55 Using Program Mode to Configure Function Blocks and Features 9 7 7 CV Periodic Timer PTIMER Introduction The periodic timer sets the discrete output CVn OS to 1 at the specified start time and periodically thereafter Use this to activate a discrete parameter at a particular time and at regular intervals In case of Warm Start If the Start Time is programmed the timer will synchronize itself to the real time clock If the Start Time is OFF the timer will continue as if the Warm Start has not occutred In case of Cold Start If the Start Time is programmed the timer will synchronize itself to the real time clock If the Start Time is not programmed OFF entered in response to time definition prompts the timer will be reset to zero and begin a new periodic cycle See Subsection 19 9 for a description of Warm and Cold Starts ATTENTION The Start Time s value cannot exceed the Period An error message is displayed if you enter a Start Time of 8 00 00 and a Period of
125. 7 10 CV Advanced Splitter Output SPLT A Introduction This function splits an input into three independently scaled outputs CVn Al CVn A2 and CVn A3 Figure 9 3 For each output when the input is between IL and IH the output is scaled between the OL and OH limits Each output holds its OL value when the input is less than the IL value for that output Each output holds its OH value when the input is greater than the IH value for that output Output limits OL and OH cannot exceed 100 but can be negatively sloped OH less than OL 100 OUTPUT VALUE 70 30 GO 90 100 INPUT SOURCE VALUE Figure 9 3 CV Advanced Splitter Default Outputs CV advanced splitter prompts Table 9 29 describes the Advanced Splitter prompts Table 9 29 CV Advanced Splitter Prompts PARM analog Prompt Range Selections Definition Full name IDPT XX XXXX Input Decimal Position Move the decimal point to XXX XXX the position used by the inputs to the CV block Input Decimal XXXX XX Position XXXXX X XXXXXX ODPT XX XXXX Output Decimal Position Move the decimal point to XXX XXX the position to be used in the output value provided by Output Decimal XXXX XX the CV block Position XXXXX X XXXXXX INP OFF Input Specify the source of the analog input Typically this is the output value OV of a Split Output Input NUMBER type of loop 5 00 UDC5300 Controller User Manual 9 61 Using Program Mode to Configure Fu
126. 8 to 371 01 1 0 0 6 N o to 2372 18 to 1300 0 1 12 4 11 3 0 005 0 009 B 110 to 300 43 to 149 06 120 7 11 2 0 002 0 003 Ee to 3300 fel to 1816 by FH R o to 3210 18 to 1766 0 1 13 2 11 8 10 002 0 003 S lo to 3210 18 to 1766 0 1 13 2 1 8 0 002 0 003 wsw2e2 o to 4200 18 to 2316 0 1 14 2 23 0 005 0 009 PLATH 100 to 2500 73 to 1371 0 1 12 6 1 4 0 005 0 009 N NIMO 32 to 2502 0 to 1372 0 1 12 5 11 4 0 005 0 009 ES lea PT100 300 to 1570 184 to 854 0 1 11 9 1 1 0 005 0 009 Pyrometry Rayotube amp Spectray Types 18890 3302 750to 1600 399to 871 0 1 typical 0 8 0 4 0 002 0 003 18890 0073 800to 1800 427to 982 0 1 typical 1 0 0 5 0 002 0 003 18890 0074 1100t02300 594101260 10 1 typical 1 2 0 6 0 002 0 003 18890 0035 1200t02600 649101426 0 1 typical 1 4 0 7 0 002 0 003 18890 0412 1375t03000 747101648 0 1 typical 1 6 0 9 0 002 0 003 18890 0075 1500t0 3300 816101815 0 1 typical 1 8 1 0 0 002 0 003 18890 1729 1650t0 3600 899101982 0 1 typical 0 9 1 0 0 002 0 003 18890 00643 1850t0 4000 1010102204 0 1 typical 2 2 1 2 0 002 0 003 18890 0216 2110t0 4600 1155102537 0 1 typical 13 5 1 4 0 002 0 003 18890 5423 2210t0 5000 1210102760 0 1 typical 3 8 1 5 0 002 0 003 18890 0163 200to 1000 9410 537 0
127. A ionen seere hes here hee Eee bare DE 17 1 17 1 MATOU 118 bes Sene R Rs eee a ENE EEN ED EET wnat Nen re oa Tema on Sree nen n ENE ERE BESS Te 17 1 17 2 IBGE SEGA CS SC HU esas she hea RER EN Sete E SEEREN ENE TEST RESENEB ERE REESE 17 2 17 3 Data StOra se Operaio ee ER Rane ae Er nr ele NE sd eee nale REESE Es 17 10 18 SETTING UP FOR SERIAL COMMUNICATIONS Guss eee Eng 18 1 18 1 DCU LOY teers ca eerste TERE NED ci settee E SENER ES FESD SEE SRI RES ERE SELE NEDE 18 1 18 2 Programming Serial Communications sssssseeeeeeereseesereeeeee nens sneen rense enn nerne 18 2 18 3 Setting the Communications Link Termination Jumper ccccccccccecceeeceesseseseeeeeeeees 18 3 19 USING MAINTENANCE MODE cccccscsceeeeseeeeeneeeeseeceeeenesonseeeneseeeesees 19 1 19 1 M OUE O SEE EN SE pte manne Smt en Ronn ERE ents Micon ne Rape Neen min Nee 19 1 19 2 alt bor Attu Anal DS ee si Resa EN a inn a area casas aces 19 2 19 2 1 Calibrating for EMF or Thermocouple Inputs ccccssssssseeeeeecceeeeeeeeeeeeessssseeeeeeeess 19 3 19 2 2 Cali brat RD Tn puts ls ane oe es ESME ESS SNS ORE SEERNES ES eee 19 4 19 3 Calibrating Analog Outputs eeeeeeeeeeeeeessssssssssssssssssssssssssssssssssssssssssssssssssesensssssssssssssssssssso 19 5 19 4 R nno Ditenesies ear ta iets ih hare ee hana BESES SEERNE Uae 19 7 19 5 Database Services Clearing Configuration and Calibration and Upgrading Optional PS SS E EE A ES T SEERNE SE sealer nee A S
128. AL AUTO key CHGA ADV OFF Change Action Selects the opposite control RATIO action from that selected for the control action Change Action cas P 1 see CTLA Control action is opposite when the CAS S 0 value of CHGA 1 or the value of the selected DIAT discrete parameter 1 SPLIT PARM discrete 9 24 UC5300 Controller User Manual 5 00 Prompt Full name To Using Program Mode to Configure Function Blocks and Features Table 9 8 Loop Prompt Descriptions Dual Tuning selection Discrete vs Keypad Setpoint Select Auto Manual Select Output Low Limit OVHL Output High Limit 5 00 NUMBER UDC5300 Controller User Manual Dual Tuning Selection A logic high 1 value for DTUN entered here or read from the selected parameter causes the loop to used the second set of tuning constants PB2 GN2 RST2 RTE2 A bumpless transfer integral term adjusted calculation will be made on transition The loop will continue to use the second set unit the value of DTUN or the selected discrete parameter 0 Discrete vs Keypad A logic high 1 value for DIKY entered here or read from the selected parameter disables the MANUAL AUTO key and selection of the setpoint using the keys on the front panel The functions are transferred to the A MS and SPSE discrete parameters See A MS and SPSE Status changes made by A MS and SPSE will remain when DIKY goes to 0 Setpoint Select
129. APPENDIX B SECURITY BYPASS PROCEDURE 2 scener B 1 X UDC5300 Controller User Manual 5 00 Tables Table 1 1 Overview of Controller Installation TaskS cc cccccccsssssssssseeeecceeeeeessaaseeeseseeeeeeeeeeeeeaaaas 1 11 Table 2e SPEC a fore 11 8 eae hee tee nut prem te tee trend DUTY ean coor SS SETE ES DO EERET rec ered SEERE TTY ROO rem 2 2 Table 2 2 Analog Input Accuracy Linear Types cccccccccccssssssssseeeeeecccceeeeseesaeaeeeesssseseeeeeeeeeeeeeeeeaaaas 2 7 Table 2 3 Analog Input Accuracy Non linear Types cccccsssssssssssseeeeeccceeeeeesaaeeesseseeeeeeeeeeeeseeeeaqaas 2 8 Table 3 1 Procedure for Unpacking and Preparing the Controller cccccccccccccseesssseeseeeeeeeeeeeeeenaas 3 2 Table 3 2 Panel Mountn Procede osiosta ia eka ade desea 3 3 Table 4 1 Wire Size Recommended Minimums ccccccccceeccccescccceecceesccceecsceecscesecseenecseeseeeneseueues 4 3 Table 4 2 GOMMUNIGATONS COMMOCIONS slots atater tere les er el ere sild KL eve uaa resulta 4 15 Table 4 3 Communications Wiring Procedure cccccccccccesscceesseceesseceesseeceesseecesseeeeesseeeesseeeeeaes 4 15 Table 5 1 Programming Required to Accomplish Connections in Figure 5 1 ecccccececceeeeeeeeeees 5 4 Table 52 Function Block Types saanen a states geben uth tessa tedden geet 5 5 Table 5 3 Function Block Output Designators 00 0 0 ccccccccccccccccessssseseseeeececceeeeeeceeeaaaaaaseseeeeeeeeeeseeeeaqaas 5 21 T
130. D ROERE JESUS ba act A S E hea 19 7 19 6 ROSE tiie Cie Tit ies Seer E a LESS SEERNE TERE EDER RER SERGE SE SSD DEER RENSE ERA SEES GET ER 19 7 19 7 Specifying the AC Power Frequency Ea ENE ne E Tera TRA lse 19 8 500 UDC5300 Controller User Manul a Ix 19 8 Displaying Firmware Version Information ccccccccccsssssssseseecceccceeeeeeeeeaaaesseeseeeeeeeeeeeeeeees 19 8 19 9 Specifying the Power Off Period for Warm Start ccccccssssssssessseeeeeeeceeeeeeeeeaeaeeeeeeeees 19 8 20 CHANGING THE CAT VAT SWITCH SETTINGS 0 cceteccceseeeeeneeeeneeseeeeees 20 1 20 1 WAVER OCC TION 4 sites a5 esate octet a eeehca te ttee au seetea a eset clic ain eee neice ceeds a SEE ENE EL SER 20 1 20 2 Settings for Current or Voltage Output ccenn E aaeei 20 2 20 3 DEEN GNC WUC NC EAE SERENE tants EDER REE SEE EEA E A A EGEDE ESBERN 20 3 2 MESSAGES Srpen 21 1 21 1 CVV CTV E HEN EESEN SENSE END NEDRE SS HENDE DSE NERE FESD EEBEESSE FEE KENDE catinc ata E action SEERE SNEDE Es 21 1 21 2 Dia MOSS Messan CS rs ire ms unde En Fad reiser hs sn neta eee oeaaren 21 2 21 3 Loop Error Indie Al OES aa ah ater SAD Al hat NS detec asad he A SN SEE et AR ERE SE NSA SE 21 5 21 4 3 8 Fe IVS SAS Sos th hate NBERER ERE RS EPE DERNE SE SERE RSD RER SSEDEJSER DE DDS REESE REE RENDE FSSEPERESEEEE H S ESEDEREEBSSBESE DREJE 21 6 22 PARTS LIS FL LEDE Ende 22 1 APPENDIX A CLEANING THE FRONT PANEL ccccesceeeeeeeneeeeseeeeeeeneesees A 1
131. DECREMENT VW keys are also used to cycle through the list of valid selections for a particular prompt 6 8 UDC5300 Controller User Manual 5 00 Modes Menus Prompts and Keypad Basics MENU key has several important functions Use the MENU key to acknowledge diagnostic and other messages When an operator display one showing process values as opposed to a menu item is on view use the MENU key to switch to the Online mode menu When a menu is already on display use the MENU key to move up a level in the menu hierarchy When in doubt where you are in the menu hierarchy use the MENU key to take you back up to something you recognize If you are already at the top level of the menu in one of the modes use the MENU key to go to the first item in the menu If you make a change to a parameter value then change your mind press MENU instead of ENTER The change will be discarded What to do when pressing MENU does nothing When you already are at the first item at the top level of the menu hierarchy in any of the three modes pressing MENU will have no effect To continue to work in the current mode use the DECREMENT VW key to move through the top level menu for the mode To go to another mode press the INCREMENT A key to display the SET MODE prompt in the lower display Note that the upper display will only ever cycle through two modes for your selection The mode not shown is the one you are already in Security
132. DO1 C DO LINEAR STD LP1 FB AO3 BC 5 00 UDC5300 Controller User Manual 7 19 Using a Factory Configuration 7 4 8 Configuration 08 108 Heat Cool with Time Proportioned Relay for Each Description This PID loop with split output uses one relay to provide a time proportioned output to the heater when the process variable is above setpoint and uses another relay to provide time proportioned output to the cooler when the PV is below setpoint A control deadband is configurable The split output is achieved with a calculated value CV function block programmed to be a standard splitter A DAT Duration Adjusting Type analog output AO function block interfaces between the loop LP block and the discrete output DO block associated with each relay In this application the AO block is not associated with analog output terminals Basic diagram Analog Input 1 PV 0 100 Wiring diagram 7 20 PID Loop 1 A Alt CQWO VYIO O O O O QIO O GO O O O CWO VYIO O O O O HEAT C Relay 1 S Time Prop CV9 C Relay 2 G Time Prop L1 L2 N Heat LOAD DO1 Cool Load LOAD Source Heat DO2 Load Source Cool UDC5300 Controller User Manual 5 00 Programming diagram 5 00 l1 TYPE LINEAR Using a Factory Conf
133. EAR Volts 0 2 V to 5 V eee EEN ITS 90 except where noted F C J Type J 0 to 2190 18 to 1199 K Type K 0 to 2500 18 to 1371 E Type E 450 to 1830 268 to 999 T Type T 300 to 700 184 to 371 N Type N 0 to 2372 18 to 1300 B Type B 110 to 3300 43 to 1816 R Type R 0 to 3210 18 to 1766 s Type S o to 3210 18 to 1766 W5W26 Type W5 W26 0 to 4200 18 to 2316 PLAT I Type Plat II 100 to 2500 73 to 1371 NINIMO Type Ni Ni Mo 32 to 2502 0 to 1372 RTD PT100 100 ohm Pt 300 to 1570 184 to 854 ATTENTION These types will be available for selection only if PYROMTRY is set to ENABLE under FEATURES in the Programming Menu as described in 9 12 903302 18890 3302 750 to 1600 399 to 871 900073 18890 0073 800 to 1800 427 to 982 900074 18890 0074 1100 to 2300 594 to 1260 900035 18890 0035 1200 to 2600 649 to 1426 900412 18890 0412 1375 to 3000 747 to 1648 900075 18890 0075 1500 to 3300 816 to 1815 901729 18890 1729 1650 to 3600 899 to 1982 900643 18890 00643 1850 to 4000 1010 to 2204 900216 18890 0216 2110 to 4600 1155 to 2537 905423 18890 5423 2210 to 5000 1210 to 2760 900163 18890 0163 200 to 1000 94 to 537 5 00 UDC5300 Controller User Manual 9 7 Using Program Mode to Configure Fun
134. ECT to SQRT then complete the engineering unit range low range high limits and other desired actions Analog outputs After the controller is placed in service you will typically be required to edit appropriate controller output settings such as impulse time for time proportioning outputs actuator speed for PP and DIAT output types output value and rate of change limits for CAT outputs Tuning parameters PID tuning parameters are configured with a default value for the Proportional term but the Integral reset and Derivative rate terms are turned off Specify a RST1 reset in tuning parameter set 1 value This may require modification when placed in service but a value other than OFF will typically provide more predictable operation For split output control loops specify a RST2 reset in tuning parameter set 2 value for the controlled cooling portion of the control output Retain the OFF state of RST1 and RST2 if Proportional Only control is to be implemented and enter a value of MRST manual reset Once the unit is placed in service experience will dictate fine tuning Tuning the loop in Online mode is described in Section 14 7 4 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Control loop ranges Update the range limits of each PID loop PV input to match the input span specified for its associated analog input In most cases analog input 1 is used as the PV of Loop 1 Note The range limits s
135. F LOAD PROFILE prompt 11 9 PRF STOR PROFILE prompt 11 8 PRG DPY1 to PRG DPY9 PRG DPYS prompts 9 74 primary displays programming 9 74 9 75 using 14 1 14 6 PROB CV CARBON parameter 12 4 process value displaying 14 4 PROD ID Maintenance menu item 19 8 PROD ID SUMMARY prompt 15 7 PROFILE Online menu item 11 5 Program mode outputs state 6 2 5 00 UDC5300 Controller User Manual Index 5 Index submenus 6 5 tasks 1 8 PROTOCOL SER COMM prompt 18 2 PSEC CV PTIMER setup parameter 9 57 PSET CV ITIMER parameter 9 54 PSET CV TOTL parameter 9 52 PTA See pretune abort messages PV LP parameter 9 16 PVHL LP parameter 9 16 PVLL LP parameter 9 16 PVTR LP parameter 9 22 pyrometry 2 8 9 7 PYROMTRY FEATURES prompt 9 7 9 77 R ranges in factory configuration 7 4 RATE SET TRND prompt 17 5 ratio control selection 9 14 ratio setpoint changing 14 4 14 6 programming 9 22 storing 17 2 RATO LP parameter 9 22 Rayotube pyrometer 2 8 9 7 9 77 15 12 replacement parts 22 1 RESET setpoint profiler STATUS prompt 11 11 resetting a setpoint profile 11 12 resetting the controller 19 7 returning unit to Honeywell 3 2 REVIEW FEATURES prompt 9 76 15 14 REVIEW Online menu item 15 14 REVIEW SECURITY prompt 9 79 RGHI AI standard parameter 9 4 RGLO AI standard parameter 9 4 RJ AI custom parameter 9 9 RLIM LP parameter 9 26 RMAN LP parameter 9 24 12 5
136. HL CV TOTL parameter 9 53 OVHL LP parameter 9 26 OVLL AO CAT VAT parameter 9 29 Index OVLL CV ITIMER parameter 9 54 OVLL CV MATH parameter 9 44 OVLL CV TOTL parameter 9 53 OVLL LP parameter 9 26 oxygen probes 12 2 P PA AO PP parameter 9 33 PA SET AO prompt 15 13 parameter values viewing and changing 6 12 6 14 PARITY SER COMM prompt 18 2 parts list 22 1 password bypass procedure 1 password configuration 9 78 password entry 6 9 PAT See PP type output PB GAIN Pretune COMP prompt 13 4 PB1 LP parameter 9 17 15 4 PB2 LP parameter 9 19 15 4 PBIN CV CARBON parameter 12 4 PCMCIA card capacities 17 7 formatting 17 3 initializing 17 3 17 10 installing 16 2 peak picking CV 9 39 9 40 percent carbon calculation See carbon potential CV periodic timer CV 9 56 9 57 PHRS CV PTIMER setup parameter 9 57 PHSE CV PTIMER setup parameter 9 57 PID control selection 9 14 PMIN CV PTIMER setup parameter 9 57 POINTI through POINT 6 SET TRND prompts 17 5 position adjusting type output See PP type output position proportioning output See PP type output power failure recovery 19 8 power frequency 19 8 power wiring 4 4 PP type output 9 13 9 33 calibrating 10 7 10 8 programming 9 34 10 2 10 6 wiring 4 13 preparing the unit 3 1 3 2 PRETUNE FEATURES prompt 9 76 PRETUNE online menu item 13 2 pretune abort messages 13 5 PRF EDIT PROFILE prompt 11 5 PR
137. HL parameter in the loop block can only by configured to be OFF or a number However in our example we want to take advantage of the fact that the CARBON type CV block calculates a value CV2 A1 representing the highest C that will not result in production of soot To use this value as the LP1 SPHL requires use of a CN block with its destination programmed as the LP1 SPHL The value from the CN block will overwrite the configured value of SPHL at runtime Table 12 11 shows the programming for the CN3 block used to accomplish this Table 12 11 CN3 Configuration for Dynamic Setpoint High Limit CN3 Programming Notes IDPT XXXXXX Set the decimal point to match CV2 ODPT si to the SPHL of LP1 Making this choice for DEST results in the CV value being written UDC5300 Controller User Manual 12 11 Carbon Potential Option Splitting the output with a CV block To implement the split output a standard splitter type CV block is needed Table 12 12 shows the programming for the CV3 block used for this purpose Table 12 12 CV3 Configuration for Splitting Output CV3 Programming Notes IDPT XXXXX X Set the decimal point to match the ODPT of LP1 ODPT XXXXX X Set the decimal point to the appropriate position INP LP1 OV The input will be the output of the PID block FB1 AO3 BC The feedback needed by the splitter will be provided by the back calculation values of the AO blocks interfa
138. HOLD OFF Hold When the HOLD 1 the active profiler is held The 1 transition of HOLD from 1 to 0 resumes the active profile at the point in its execution it had reached before it was held PARM discrete 11 4 UDC5300 Controller User Manual 5 00 Configuring and Using Setpoint Profiler 11 4 Setting Up a Profile Introduction To set up a profile select PROFILE from the Online mode menu PROFILE will appear only if the Profiler is in the READY or ENDed state Next select PREF EDIT Profile Edit prompts Table 11 2 describes the Profile Edit prompts ATTENTION Be sure to read and follow the instructions for configuring the last segment of a profile These instructions appear after Table 11 2 Table 11 2 Profile Edit Prompts Prompt Range Selections Definition Full name T UNIT SECS Time Units Specify the time unit of the profile Time Units MINS HOURS Specify the limits to be used when the value of the DVPLL OFF Deviation Hold Low Limit and Deviation Hold High Limit pein elton parameter specified for DP L1 or DP L2 typically LPn PV ow Limit is compared to the profiler output value SP1 OV DVPHL If the deviation is outside these range limits the profile will lt a be held until the deviation is not outside the range Deviation Hold High Limit See Table 11 1 to program DP L1 and DP L2 The controller will cycle through the remaining prompts in this table 16 times Use each
139. Honeywell UDCS5300 Controller User Manual 51 52 25 58 Rev 1 5 00 Sensing and Control gt gt Copyright Notices and Trademarks Printed in U S A Copyright 2000 by Honeywell Revision 1 5 00 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 The foregoing is Buyer s sole remedy and is in lieu of all other warranties expressed or implied including those of merchantability and fitness for a particular purpose Specifications may change without notice The information we supply is believed to be accurate and reliable as of this printing However we assume no responsibility for its use While we provide application assistance personally through our literature and the Honeywell web site it is up to the customer to determine the suitability of the product in the application SYMBOL DEFINITIONS 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 electric shock This symbol on the equipment warns the user of potential shock hazard where voltages greater than 30 Vrms 42 4 Vpeak or 60 Vdc
140. Hyst LTE Result goes OFF when Input 1 Input 2 gt Hyst See Figure 9 5 CONDITION TYPE amp amp NDITION HYSTERESIS 2 SLS Figure 9 4 Compare Signal Flow 5 00 UDC5300 Controller User Manual 9 65 Using Program Mode to Configure Function Blocks and Features Operator GT Greater than HysteresB 2 degrees Input 1 gt Input 2 Result switches ON nput 2 Input 1 gt Hysteresis esult switches OFF Result OFF Result OFF Figure 9 5 Compare s Greater Than Result With Hysteresis 9 66 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 8 Programming Alarms Up to four process alarms can be programmed on the controller When an alarm condition occurs a display indicator will light to alert the operator In addition a relay can be used for control or alarm annunciation when a process alarm occurs See 9 6 for DO programming instructions To program alarms select PRG AL on the Main Program Menu Select an alarm to program ATTENTION Alarms are configurable only if ALARMS is set to ENABLE under FEATURES in the Programming Menu as described in 9 12 Alarm prompts Table 9 31 describes the Alarm prompts Table 9 31 Alarm Prompts Prompt Range Selections Definition Full name ACTN Action Specify the alarm action Action NONE None No alarm action HIGH High Alarm condition when input value gt
141. IN enter initial FURN value This value can be changed online IDPT XXXXX X Set the decimal point to the appropriate position INEU NONE Set input engineering units to NONE DEST OFF _ The application does not require that the CN value be written to any destination The application does not require that the CN value be written to CO value required for C calculation In order for the C to be computed correctly by the CARBON type CV block the percent carbon monoxide in the carburizing gas must be specified using CV2 CO This can be a dynamic value from an analog input However in our example a fixed value is entered Instead of entering the value directly for the CO parameter during configuration of CV2 a CN constant block is selected as the source of the value This enables the CO value to be displayed and changed ona PVCN primary display while the controller is online Table 12 8 shows the programming for the CN2 block 5 00 UDC5300 Controller User Manual 12 9 Carbon Potential Option Table 12 8 CN2 Configuration for CO Value CN2 Programming Notes IN nnnnn n Enter initial CO value This value can be changed online IDPT XXXXX X Set the decimal point to the appropriate position INEU NONE Set input engineering units to NONE DEST OFF The application does not require that the CN value be written to any destination CARBON type CV block
142. INEAR pH CONTROLLER TRANSMITTER See ee 4 TO 20 mA SP 7 00 i OUT 90 5 pH DAT CONTROL SIGNAL CAUSTIC DE REAGENT PUMP WASTE WATER TREATMENT VESSEL WITH IMMERSION STYLE pH ELECTRODE AND MIXING IMPELLER Figure 8 7 Control of Wastewater pH Using a Time Proportioning DAT Control Signal This application requires a basic time proportioning control loop to monitor and control the pH of the wastewater to a local set point of 7 pH units That is the loop will neutralize the wastewater so that it can be safely released to the environment The wastewater pH which is assumed to be primarily acidic will be controlled by introducing a caustic reagent to the contents of the treatment vessel This will be done through use of a time proportioning relay signal that will pulse a pump connected to a caustic reagent source A function block diagram representing the control scheme of Figure 8 7 has been drawn in Figure 8 8 The same diagram method was used to produce Figure 8 6 5 00 UDC5300 Controller User Manual 8 7 Learning to Create Custom Programs CONNECT TYPE STANDARD CIRCUIT HIGH 5 SP1 7 00 IMPULSE TIME 150 Figure 8 8 Function Block Diagram of Figure 8 7 This drawing is similar to the temperature control application The analog input control loop and analog output function blocks AI1 LP1 and AO1 have been used similarly The discrete output function block was added drawn as a circle at AO1 s apex
143. If you choose INITTYPE CURRENT the card is initialized using the current setup the setup from the last initialization not the new setup Typically the online operator will use INITTYPE CURRENT to continue the same storage settings onto a new card ATTENTION Initialization deletes any data already on the card therefore you must press ENTER at the SURE prompt to proceed To cancel press MENU 6 Verify that the new setup is being stored by viewing the DS STATS menu SETUP should indicate CURRENT If NOT CRNT an initialization error may have occurred repeat the initialization NOT CRNT means that a new setup is pending but is not in effect 5 00 UDC5300 Controller User Manual 17 3 Storing Data Specifying storage mode Select DS SETUP Data Storage Setup to specify storage mode and other settings DS SETUP provides access to a submenu to establish a data storage schedule of parameters storage rates and response characteristics Press ENTER to access the submenu and when exiting press ENTER at the SAVE prompt to retain setup selections Table 17 3 describes the DS SETUP prompts Table 17 3 DS SETUP Prompts SET TRND Set Trend see Table 17 4 Lets you store points that can be displayed graphically on a PC using Honeywell SDA software SET AED Set Alarms Events Diagnostics See Table 17 5 Lets you store all alarms events and diagnostics Setting up trends Table 17 4 describes the SET TRND prompts Tab
144. If you plan to program another function block to use a calculated value as its input you must program the CV first UDC5300 Controller User Manual 5 00 Planning Diagram Calculated Value CV INPn OV output value PV Same as input from 1 to 8 inputs value to peak pick depends on type and totale pt INPn F po analog out n RST BC O reset peak pick back calculation totalizer interval value timer periodic timer ASEL amp analog switch signal select only DSEL D n C discrete switch discrete a C signal select only FB OS feedback eter output status gt FB1 FB2 FB3 feedbacks advanced splitter only PSET amp preset value totalizer and interval timer only PBIN probe in carbon potential only TPIN temp in carbon potential only CO CO comp carbon potential only FURN furnace factor carbon potential only 5 00 UDC5300 Controller User Manual 5 11 Planning 5 2 4 5 Constant Block Use Constant CN blocks can provide values for use by other function blocks as tuning constants slew limits setpoint limits and as the DAT impulse time Do not let the name fool you While the CN block can be configured to provide a fixed number truly a constant as its output it can also be programmed to receive a variable as its input from another block then write this value to another block s input Input
145. Indicates the number of event records remaining before the memory card event file is full Indicates the number of diagnostic records remaining before the memory card diagnostic file is full Indicates DS SETUP status CURRENT Setup has not changed since last initialization NOT CURRENT Setup has changed since last initialization Indicates the trend capacity based on the storage rate and number of points being stored Shown as follows 00 00 00 Days Hours Minutes Checking batch number BT NUMBER Batch Number This item appears only if BATCH mode is selected Shows the number of the current batch being stored The number may be used later with the SDA software to locate data Checking card contents DS FILES Data Storage Files Provides a directory of the files on the memory card The directory may be used to review any data file type including configuration and profiles Press ENTER to select DIR Use DECREMENT and INCREMENT A to see all files 17 12 UDC5300 Controller User Manual 5 00 Storing Data Data storage messages 5 00 The following messages may appear during data storage operation Pressing any button will clear the message Table 17 10 Data Storage Messages MCARD NOT CURNT When the memory card is initialized the controller marks it as the current card The controller will only store data to the current card If any other card is used this message will appear
146. LE menu item ROLLOVER ENABLE Rollover enabled causes new data to replace the oldest External Enable DISABL data when the file is full old data will be lost Rollover disabled causes storage to stop when the file becomes full new data will be lost Specifying the discrete to start and stop batch data collection BT SETUP Batch Setup appears only if BATCH mode is selected as the storage mode for trends or alarms events and diagnostics Select a discrete parameter or none that will start and stop storage in numbered batches When this discrete is on 1 the batch number increments and storage begins When off 0 storage stops and the batch ends 17 6 UDC5300 Controller User Manual 5 00 Storing Data ATTENTION If no parameter is defined for BT SETUP batch storage is controlled instead through the online STORAGE menu item BT CTRL If a parameter is defined for BT SETUP BT CTRL is disabled Memory card capacities for trend storage The number of hours a single memory card can store trend data depends on a the card type 256 K 512 K 1 Meg b the number of points for which trend data is collected c the sample rate at which trend data is collected d whether or not the controller is configured to collect alarm event and diagnostic messages When SET AED prompt STRG MOD is set to CONT or BATCH space on the memory card is allocated for the storage of 100 alarms 100 events and 100 diagnostic messages When STRG MOD
147. Limit and Input High Limit Specify the NUMBER display limits used only by the SCF software NONE Input Units Specify the unit of measure degrees E Fahrenheit or Celsius of the input C UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 32 Constant Prompts Prompt Range Selections Definition Full name DEST OFF Destination Select the string representing the function block parameter which will use the constant from this block DESTINATION PARM See Destination Programming Issues below If PARM is selected the following block and parameter combinations are available None No destination CN value not used AOn DS AOn DSLW Decreasing Slew Limit AOn IS AOn ISLW Increasing Slew Limit AOn HS AOn INHL Input High Limit AOn LS AOn INLL Input Low Limit AOn IT AOn IMPT DAT Impulse Time PTn GN not used PT1 PB not used PTn RS not used PTn RA not used LPn DS LPn DSLW Decreasing Slew Limit LPn IS LPn ISLW Increasing Slew Limit LPn HS LPn SPHL Setpoint High Limit LPn LS LPn SPLL Setpoint Low Limit LPn GN Loop n GN1 Gain 1 LPn RS LPn RST1 Reset1 LPn RA LPn RTE1 Rate1 LPn RB LPn BIAS LPn PB LPn PB1 Prop Band1 Destination programming issues When programming loop LP blocks and analog output AO blocks some parameters such as proportional band or
148. Mounting 3 Unpacking Preparation and Mounting 3 1 Overview This section contains instructions for unpacking preparing and mounting the controller Instructions for wiring are provided in Section 4 What s in this section The following topics are covered in this section Topic Page 3 2 Unpacking and Preparing 3 2 3 3 Mounting 3 3 5 00 UDC5300 Controller User Manual 3 1 Unpacking Preparation and Mounting 3 2 Unpacking and Preparing Procedure Table 3 1 contains the procedure for unpacking and preparing the controller Table 3 1 Procedure for Unpacking and Preparing the Controller ATTENTION For prolonged storage or for shipment the instrument should be kept in its shipping container Do not remove shipping clamps or covers Store in a suitable environment only See specifications in section 2 2 Compare the contents of the shipping container with the packing list e Notify the carrier and Honeywell immediately if there is equipment damage or shortage e Do not return goods without contacting Honeywell in advance 3 Remove any shipping ties or packing material Follow the instructions on any attached tags and then remove such tags number on the nameplate to verify that the instrument has the correct optional features See Section 2 for model number breakdown 4 All UDC5300 Controllers are tested at the factory prior to shipment Examine the model designed for installation in
149. P cascade primary loop CAS S cascade secondary loop CAT current adjusting type output selectable between 0 mA to 20 mA CV block calculated value type function block DAT duration adjusting type output also known as time proportioned uses a single relay increase and decrease PID proportional integral derivative control algorithm PLC programmable logic controller PP position proportioning output using slidewire feedback via analog input two relays used for output one each for increase and decrease PV process variable VAT voltage adjusting type output selectable between 0 V and 5 V UDC5300 Controller User Manual 5 00 Table 5 5 Single Loop Factory Configurations Planning DAT for cool Number identifying the strategy when loading as described in Section 7 Load I O Control Input Output Special Application Number Hardware Type Signals Signals Features Model Needed Selection 100 no preconfiguration factory defaults 01 In 1 analog STD analog PV CAT any PID with 101 Out 1 current standard PID current output 02 In 1 analog SPLIT analog PV CAT for heat CV block splits heat cool with 102 Out 2 current PID with split output current output for output and each CAT for cool 03 In 1 analog SPLIT analog PV CAT for heat CV block splits heat cool with 103 Out 1 current PID with split output current out for heat 1 relay output and and DAT for cool
150. P1 s output This will allow the generation an LP2 set point that will induce a process upset when the secondary loop is placed back in automatic mode Only after LP2 has been tuned can LP1 be tuned When tuning LPI LP2 will be kept in automatic mode throughout the entire time LP1 is exercised Since the tuning of LP2 will have already been established tuning LP1 may be approached by first mentally blocking out the secondary control loop s existence and visualizing LP1 s output as connected to a sort of virtual analog output function block In this light tuning the overall cascade control configuration becomes the considerably simpler matter of tuning a single control loop UDC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 Using Program Mode to Configure Function Blocks and Features 9 1 Introduction Overview This section describes all the prompts used in Program Mode to configure individual function blocks In addition other Program Mode operations such as copying a block and enabling disabling features are described A few tasks accomplished in Program Mode are not described in this section Instead those tasks are described in separate sections e loading a factory configuration see Section 7 e configuring Setpoint Profiler see Section 11 e configuring the optional carbon potential type CV calculated value block see Section 12 e storing and loading c
151. POINT PRGM key 11 10 SET TRND DS SETUP prompt 17 4 SET YEAR SET CLK prompt 9 80 SETPOINT PRGM key functions 6 17 11 1 11 10 setpoint profiler loading and storing profiles 11 8 11 9 programming 1 1 1 11 7 using a profile 11 10 11 12 setpoint profiler block See SP block setpoint selection disabling 9 25 using Online menu 15 3 15 6 using primary display 14 4 setpoints changing value 14 4 14 6 disabling switching 9 79 displaying 14 4 programming 9 20 storing values 17 2 SETUP DS STATS prompt 17 11 17 12 SHR CV PTIMER setup parameter 9 57 SIG AI custom parameter 9 9 signal selection CV 9 41 9 42 signal wiring 4 6 slidewire feedback powering 20 2 SLWR AO PP parameter 9 33 SMIN CV PTIMER setup parameter 9 57 Snn DV1 PROFILE prompt 11 6 Snn DV2 PROFILE prompt 11 6 Snn EV1 PROFILE prompt 11 6 San EV2 PROFILE prompt 11 6 San TIM PROFILE prompt 11 5 Snn VAL PROFILE prompt 11 5 SOOT CV CARBON parameter 12 5 Index 6 UDC5300 Controller User Manual 5 00 SP Pretune IDENT and CALC prompt 13 4 SP block description 5 18 programming 11 3 11 4 SP PRFLR Online menu item 11 11 SP1 ensuring display 12 13 SP1 SP2 SECURITY prompt 9 79 SP2 use with setpoint profiler 11 2 specifications 2 2 2 8 Spectray pyrometer 2 8 9 7 9 77 15 12 SPHL LP parameter 9 21 SPID LP parameter 9 22 split output 9 59 and loop type selection 9 14 example 8 9 split
152. PP 10 6 10 4 Calibrating 10 7 5 00 UDC5300 Controller User Manual 10 1 Position Proportioning Output Setup and Calibration 10 2 Configuring the Blocks Used for PP Introduction Figure 10 1 shows factory configuration 11 111 in Table I of the model selection guide This is a representative example of PP configuration Note however that other loop types can be used with PP output and that with one exception any available hardware inputs output and relays with their associated function blocks can be used The exception is that the slidewire feedback input must always use hardware analog input 2 Program block AI2 without lag There is nothing special about CN9 used by this configuration any appropriately configured CN block will do 11 TYPE LP1 PV LP1 TYPE AOS INP LINEAR Ali OV STD LP1 OV CO poz LP1 FB AO3 BC AO3 TYPE PP AO3 PA PP AO3 INC DO1 AO3 DEC DO2 12 TYPE AO3 SLWR Al2 OV LINEAR CN9 IN AO1 INP 20 CN9 OV AO1 TYPE VAT AQ1 INLL 0 AQ1 INHL 100 AO1 OVLL 0 AO1 OVHL 5 Figure 10 1 Factory Configuration 11 111 Check analog output switch setting Before beginning this configuration verify that the analog output hardware to be used to power the slidewire feedback is set to provide voltage output instead of current This is set using switches on the card with the analog output hardware Sec
153. PROTECTIVE EARTH terminal shall be connected to the supply ground Noise suppression Protect the controller from noise sources such as e relays switching inductive loads e switching solid state devices SCR s etc e welding machines e nearby conductors carrying heavy currents e fluorescent lights e thyratron and ignition tubes e neon lights e communications equipment e common impedance conductive coupling e magnetic inductive coupling e electromagnetic radiation coupling To minimize electrical noise and transients that may adversely affect the system supplementary bonding of the control enclosure to a local ground using No 12 4mm copper conductor is recommended To protect outputs use the techniques in Figure 4 1 44 UDC5300 Controller User Mnual 0 5 00 Wiring ATTENTION In exceptional cases where the device connected to a relay contact requires a very low nominal energizing current it is possible that the current through the snubber network capacitor s located on the circuit card and used to protect relay contacts from arcing when the relay contacts are open will be sufficient to continue to energize the relay To prevent this unwanted energizing install a load resistor in parallel with the device Instrument Instrument cy S S S Relay or See Parts ZX 4 to 20 mA 0 1 mfd Phase Angle Discrete Table below Aut 400V Firing Output p Part 023794
154. S ES ESTERE Bee ELERS RES BE REESE RENEE SEERNES ES ects 9 69 9 10 COP aAa DIOCESAN 9 73 5 00 UDC5300 Controller User Manual vii 9 11 Programming Primary Displays arciasnesossesstahastctalwcidanaconiunds eauhaeaedmoibicaneaiundd aes shetabaeadatenucen2 9 74 9 12 Pai lame 92 TE VD 5 Sieen a a a a e 9 76 9 13 PEO Sham IMS SCC I ar Vecsei ERE ENES KERES TERESE TEE SEE NERE ENRON alent eat edad 9 78 9 14 SUS HEAD WIN COC Mea ds os hace Eee REESE SEERE TEDE RE SSEEE EF SEE BEES NE EET E ERE ES eee 9 80 9 15 Specifi yne Me Scam Tregun esras ana slasher samushel en aces stele cunnaes 9 81 9 16 Selectine Display Wane ase el case aeeaerdean a eae t een eevee encase 9 82 10 POSITION PROPORTIONING OUTPUT SETUP AND CALIBRATION 10 1 10 1 I Cola ere CHOTA ecstatic ee ects lear sein tas Seen E andente mannii 10 1 10 2 Configuring the Blocks Used for PP u ccccccccccccccccccccecceeesseseeeeceeeceeeceeeseeeaaaaaaeaseeeseeeess 10 2 10 3 Wine the Controler TOPP aise sari ie NER ai E stare tae E shat tadu restates 10 6 10 4 A ANEW AUN os ica ecco cs edna E N 10 7 11 CONFIGURING AND USING SETPOINT PROFILER ss 11 1 11 1 Tatrou CCCI hss tates ek eee etc SEES SER SEE a ate sats SETE REDER salsa anaes 11 1 11 2 IVE SCIP OG sos aci ssa aosn ean seas cecheenacecicegantiacaneaenetenceces sa iseaaemtecasansaneee soatnisaann as aeacsaseeuace 11 2 11 3 Defining the Profiler mpitsandR n En 5 sone an onen le EA a allel se ledes 11 3 11 4 Sct UP ERO essai chia
155. Ss coe S S TS DORAL INC Al2 DEC 7 26 UDC5300 Controller User Manual 5 00 Programming diagram 5 00 l1 TYPE LINEAR 12 TYPE LINEAR Using a Factory Configuration LP1 PV LP1 TYPE AOS INP Al1 OV STD LP1 OV LP1 FB AQ3 SLWR Al2 OV AO3 BC AO3 TYPE PP AO3 PA PP AQ3 INC DO1 AO3 DEC DO2 CN9 IN 20 AO1 INP CN9 OV AO1 TYPE VAT AO1 INLL 0 AO1 INHL 100 AO1 OVLL 0 AO1 OVHL 5 UDC5300 Controller User Manual 7 27 Using a Factory Configuration 7 4 12 Configuration 12 112 PID Ratio Control with Position Proportioning Relays Out Description This strategy keeps the controlled variable in ratio with the wild variable Both variables are supplied as linear analog inputs each served by an analog input AI block Two relays are used for position proportioning output An analog output AO block with both its type and its positioning algorithm set to PP position proportioning interfaces between the loop LP block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO block is not associated with analog output terminals The analog feedback signal from the positioner s slidewire is received at AI2 The feedback is powered by a constant 1 V from the terminals associated with AOI and its VAT voltage adjusting type AO func
156. T Duration Adjusting Type analog output AO function block interfaces between the Loop 1 LP1 block and the discrete output DO block associated with the time proportioned relay An analog output AO block with its type set to PP position proportioning and its positioning algorithm set to DIAT interfaces between the Loop 2 LP2 block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO blocks are not associated with analog output terminals Basic diagram Analog Input 1 F ve 1 C Relay 1 0 100 i Time Prop INC Analog Input 2 Relay 3 y PID Loop2 0 100 i DEC Relay 4 DIAT Wiring diagram Actuator Voltage Alt DO3 DK oa iis INC QO LOT Oa 4 DEC CO OE poa A OQ LO Oa i OQ Oy LOT amp ree SURE E OQ E E S YQ LOH LO OQ LOT LO amp Al2 7 50 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Programming diagram Al1 TYPE LP1 INP LP1 TYPE AO3 INP LP1 OV DO LINEAR Al1 OV STD LP1 FB AO3 BC AO3 TYPE DAT AO3 OUT DO1 O nos Al2 TYPE LP2 INP LP2 TYPE AO4 INP LP2 OV LINEAR Al2 OV DIAT oos i LP2 FB AO4
157. TUNE from the Online menu Select LP1 or LP2 to tune Pretune occurs in four stages as indicated by the status PT STATUS Each status has its own menu Table 13 1 shows the stages of pretune Table 13 1 Stages Of Pretune Order Status Meaning 1 STOP Pretuning not operating waiting to be started by operator See STOP menu 2 IDENT Pretune is identifying process dynamics as a result of a setpoint or output change See IDENT menu 3 CALC Identification is complete and calculation of new tuning parameters is in process See CALC menu 4 COMP Calculations are complete and new parameters are ready to replace the loop s tuning parameters if desired See COMP menu STOP menu Table 13 2 describes the Pretune STOP prompts Table 13 2 Pretune STOP Prompts Tuning Set Prompt Range Selections Definition Full name PT STATUS Status stopped PT TSET Select which set of tuning If tuning a split loop set 1 applies to loop output parameters 1 or 2 will between 0 and 100 set 2 applies to loop output be pretuned and installed between 0 and 100 PT OPTZ Select SET PT or LOAD This optimizes the new tuning parameters according to their intended use that is controlling changes in Optimize setpoint or process load PT OSHT Select YES or NO This determines whether or not some overshoot is acceptable in the pretune specified tuning Overshoot i i 2 g 13 2 UDC5300 Controller Use
158. This takes the place of the TOGGLE SPT item on the Loop Tuning Menu when the Discrete vs Keyboard DIKY discrete has a value of 1 If SPSE 1 then Setpoint 2 is used If SPSE 0 then Setpoint 1 is used When DIKY or SPSE is OFF SPSE has no effect Auto Manual Select This takes the place of the MANUAL AUTO key when the Discrete Vs Keyboard DIKY discrete has a value of 1 If A MS 1 then Manual Mode If A MS 0 then Automatic mode When DIKY or A MS is OFF A MS has no effect Output Low Limit and Output High Limit Use these to specify the range of the output of the primary loop in a cascade control strategy This primary output range should match the range specified for the PV of the secondary loop Usually the loops should be configured so that LP1 OVLL LP2 PVLL LP1 OVHL LP2 PVHL 9 25 Using Program Mode to Configure Function Blocks and Features Prompt Full name Loop Bad Action Required 9 26 Applies To Table 9 8 Loop Prompt Descriptions Range Selections NUMBER range is 100 to 200 NO UC5300 Controller User Manual Interacting When YES is selected the Gain or PB reset and rate terms interact When NO is selected Gain affects reset and rate but rate and reset do not affect Gain more closely approximating analog control Reset Limit Enter value to restrict the calculated integral term of the loop during cold start see 18 9 or upon tra
159. UDC5300 Controller User Manual 5 00 Wiring diagram Programming diagram All TYPE LINEAR Al3 TYPE LINEAR Al2 TYPE LINEAR 5 00 Using a Factory Configuration ENKE REE A E Sa L1 Actuator QT FO QO SH L2 N Voltage ME OF O 56 M Sr ES LS INC OS OST ERS 109 SET Or O Bee OQ Oa O Ne INC Al2 DEC Al3 LP1 PV LP1 TYPE AO2 INP AO2 TYPE Al1 OV STD LP1 OV CAT LP1 FB AO2 BC C DO1 LP2 PV LP2 TYPE AO3 INP Al3 OV STD LP2 OV DO2 LP2 FB AO3 BC AO3 TYPE PP AO3 PA PP AO3 INC DO1 AO3 SLWR Al2 OV AO3 DEC DO2 CN9 IN AO1 INP 20 CN9 OV AO1 TYPE VAT AO1 INLL 0 AO1 INHL 100 AO1 OVLL 0 AO1 OVHL 5 UDC5300 Controller User Manual 7 41 Using a Factory Configuration 7 4 20 Configuration 20 220 Two Independent PID Loops One with Current Output and One with Direction Impulse Adjusting Relays Out Description Two independent loops each each have a linear input served by an analog input AI block to supply the process variable to the loop Loop 1 is a standard PID loop with a CAT current adjusting type analog output AO block Loop 2 provides PID control using direction imp
160. User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 12 PP Analog Output Prompts 5 00 UDC5300 Controller User Manual Prompt Applies Range Selections Definition Full name To IDPT all XX XXXX Input Decimal Position Move the decimal i Deema output XXX XXX point to the position to be used in the input value Input Decimal types XXXX XX provided to the AO block Position XXXXX X XXXXXX INP all OFF Input Specify the source of the input to the AO output function block Input types NUMBER PARM analog DUSE PP OFF Drive Unit Sensitivity Enter the largest value Drive Unit NUMBER that does not cause drive motor oscillation SES LIV range is 80 to 100 DUSP PP OFF Drive Unit Speed The full scale travel time for h Drive Unit NUMBER cae Aben range is 1 to 300 seconds SLWR PP OFF Slidewire Feedback Source The Al block associated with the hardware input connected to Slidewire NUMBER the slidewire typically Al2 Feedback PARM Source analog The range of the feedback analog input must be programmed for engineering units of 0 to 100 units indirect range with a circuit span of 0 to 1 Vdc PA PP AUTO Positioning Algorithm Specify the appropriate ieee algorithm The rules are Positioning PP Algorithm DIAT e AUTO and DIAT algorithm can be used only with DIAT loop type e PP algorithm can be used only with loop types other than DIAT e PP and AUTO
161. When the controller is shipped from the factory analog output 1 AO 1 is always a current output Whether the second optional analog output provides a current output or a voltage output depends on the model selected see Section 2 However analog outputs can be converted from current to voltage output or vice versa using the procedure in this section to change DIP switch settings on printed circuit cards in the controller What s in this section The following topics are covered in this section Topic Page 20 2 Settings for Current or Voltage Output 20 2 20 3 Setting the Switches 20 3 5 00 UDC5300 Controller User Manual 20 1 Changing the CAT VAT Switch Settings 20 2 Settings for Current or Voltage Output Introduction The setting on switchbank S1 on the printed circuit cards providing analog outputs determines whether those outputs will be current or voltage Either can be used as the output of a control loop When two relays are used to provide position proportioning output a VAT output is used to provide a constant 1 V to power the required slidewire feedback Switch settings Table 20 1 shows the switch settings needed to select current or voltage output Table 20 1 S1 DIP Switch Settings S1 1 S1 2 S1 3 S1 4 cm oF OF o ON Po ovat o o o oF 20 2 UDC5300 Controller User Manual 5 00 Changing the CAT VAT Switch Settings 20 3 Setting the Switches Introdu
162. X iD DU Slave any address DC ma sla e OC erminated DT Figure 4 11 Network Data Cable Connections Slave any address Slave any address Last slave must be terminated 416 0 0 0 UDC5300 Controller User Mnual 0 5 00 5 1 Planning 5 Planning Overview Introduction When programming your controller you have two options e Begin function block programming from scratch Using this freeform approach means that you do all the programming required to link function blocks for data flow and specify the operation of every block needed to process inputs execute a control algorithm and make the output available to field devices e Begin with one of the built in factory configurations and customize it for your application Factory configurations use the same function block types as the freeform approach However when using a factory configuration the basic data flow between function blocks has already been established Your job is to specify site specific values such as tuning parameters and if necessary to link additional function blocks to the factory configuration to accommodate special requirements of your application If you are a first time user of the UDC5300 we strongly recommend that you read this section It provides information to help you make this decision Specifically it provides e information about the capabilities of each type of function block e a description of each factory configur
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164. a ipsich sett acces eign bina taste cated cp a T 15 7 eae 54 Al CS assay a cscsstenices N ania cot ERE ES ES ESTERE ELERS NER 15 8 Table 15 5 Procedure for Viewing Alarm Types and Setpoint ccccccccccecceccceeeseeseeseeeeeeeeeeeeaaaas 15 9 Table 15 6 How To View Diagnostic MeSsages cccccccccccsssssssssssseeeccccceeeeeseaeaasseessseesseeeeeceeeeeeeeeaaas 15 10 xii UDC5300 Controller User Manual 5 00 Table 15 7 How To Clear Diagnostic Messages M1 W W MW ssssseesereereeseeeeeeee essensen renen essens eashetabeaeebiadwoads 15 10 gf Best bcs yer tam Datt By gl ego 0 201 8 Ec ame re Ca vet tim Rete ee CU REESE nee SAIC CON Cee BRED SER SEES EESEDOEN 15 11 Table 15 9 Procedure for Changing Alarm Seto orientere ae enables 15 12 Table 15 10 Tunable Analog Output Parameters cccccssssssseseseeceeeeeeeeceecaaaaeeseseeeeeeeeeeeeeeeaaas 15 13 Table 15 11 Procedure for Viewing Program Settings ccccccccccssssssssseeecceceeeeceeaeaeeesesseeeeeceeeeeeeaaaas 15 14 Table 16 1 Memory Card Installation and Removal Procedure cccccccccccceeeeessseseeeeeeceeeeeeeeeaaaas 16 2 Table 16 2 Procedure for Storing Configuration and or Calibration ccccccecccccsessssseeeeeeeeeeeeeeeeaas 16 4 Table 16 3 Procedure for Loading Configuration and or Calibration ccccccccccssssssesseseeeeeeeeeeeeaaas 16 5 Tables V7 el Evente Str ace a hasta nalelivaea a a E tees 17 2 Fable 7 2 Data Storage Seti Procede sc
165. able 15 9 Table 15 9 Procedure for Changing Alarm Setpoint 2 To view and or edit an alarm setpoint press ENTER 3 Scroll to Alarm 1 through 4 and press ENTER The alarm type and current setpoint will be displayed 4 To change the setpoint edit as you would any number press ENTER to move the cursor to the data line and the display will change to the word NUMBER Press ENTER to indicate that you want to edit the number or scroll to the OFF choice to disable the alarm If you press ENTER the current value will again be displayed 15 12 UDC5300 Controller User Manual 5 00 Using Online Menu Functions line Adjusting Analog Outputs You can adjust analog outputs using the SET AO item on the Data Entry menu Tunable parameters depend on the AO type selected CAT VAT DAT PP The tunable parameters for all AO types are identified in Table 15 10 Input bias and gain can be adjusted using the DATA ENT item on the Online menu see Table 15 8 To tune Analog Outputs select SET AO on the Data Entry menu Select an AO to adjust Table 15 10 Tunable Analog Output Parameters Prompt Range Selections Definition Full name DUSE Adjust the value to the Applies to PP type AO only This is a percentage value desired amount between This value should be set to the highest number which Drive Unit 80 and 100 does not cause drive motor oscillation Sensitivity ae to be used PP DIAT or
166. able 5 4 Abbreviations Used in This Section W W W u ssseesesesseeseseseseseeeee sene eee ennen ennen eee n renerne nere 5 24 Table 5 5 Single Loop Factory Configurations ccccccccccccccccceeeeseeseeeceeceeeeeeeeeeeuaaaaeseeeseeeeeseeeeeeaaaas 5 25 Table 5 6 Two Loop Factory Conti curation cisterna canes eo a re aus esl eae ened 5 27 Table 6 1 Procedure for Entering a NUMbET ccccccccccccccesesseesesescccceceeeeeeeeaaaaeesesseeeeceeeeeeseeeaqaqaaas 6 13 Table 6 2 Procedure tor Sclecine a Parameter cs aa inn a E AAS 6 14 Table 6 5 Key Punc HONS tint secsncses sortere ce suetaimceshod S 6 15 Table 6 4 Example Procedure for Selecting an Item ccsssssssseeeeecceeeeeeeeeeeaaeeeesseeeeeeeeeeeeeeeeas 6 18 Table 9 1 Analog Input Algorithm Type Definitions 0 0 0 0 cccssssssssesseeeeeceeeeceeeaasseesssseeeeeeeeeeeeeaaaas 9 3 Table 9 2 Standard AI Algorithm Prompts ccccccccccccccccceeceeesssseeeeececceceeeeseeaeaaeesssssseeeeseeeeeessaaaas 9 4 Table 9 3 Analos Input Py DER saae sd dscasesnatetdraancenvets t 9 7 Table VA Custom ALA onthi Prompts x cts eats seas eee done bi alana acai dial taal Grade an eeteen 9 9 Table 9 OSCE hate tee og andet a a aA Kender 9 13 Fable 920 Loop TYPE Sia ies BUNKER dake Sasi eed ted bd cies adds washout ied oe BERN USL SELERSENJESERE SIGE SEERE URE 9 14 Table 9 7 Control Loop Prompts series Ea 9 15 Table 9 5 Loop Prompt DeSCr pris zisne anede eder ao dar are jalan tare
167. ace temperature that will avoid production of soot When used in conjunction with other function blocks this carbon potential block is useful for applications such as carburizing the surface of low carbon steel and heat treating carburized parts as well as in atmosphere generating applications Serial communication An optional serial communications card permits use of the UDC5300 with up to thirty other devices on a multi drop datalink from a personal computer using either the traditional Honeywell binary or Modbus RTU protocols Setup for serial communication is described in Section 18 Data storage 1 4 The controller can be equipped with a PCMCIA Personal Computer Memory Card International Association storage card interface to store process data log alarms and events save controller configurations and calibration and maintain multiple setpoint profile files The PCMCIA card interface accepts 256KB 512KB and 1 MB SRAM memory cards Data storage can be continuous or linked to certain events To view and analyze data including trends from these cards use Honeywell SDA software running on a personal computer Use of the data storage feature is described in Section 17 UDC5300 Controller User Manual 5 00 Introduction Password protection Protect your choice of operator functions using a configurable three digit password A second master password can be specified to protect the integrity of the controller s configu
168. al use that matches the configuration s use of AI AO DI and DO function block types WARNING The diagrams in this section are intended to supplement not replace the instructions in Section 4 Wiring Be sure to read and understand Section 4 before attempting to connect power or signal wires Turn power off at mains before installing AC power wiring Note that in the diagrams a cross hatched triangle DP represents an analog output function block that is not associated with analog output hardware 5 00 UDC5300 Controller User Manual 7 7 Using a Factory Configuration 7 4 1 Configuration 01 101 PID with Current Output Description This is the most basic PID control loop a linear input served by an analog input AI block supplies the process variable to a standard PID loop The output is through a CAT current adjusting type analog output AO block Basic diagram Analog FR Analog Input 1 is Output 1 Loop1 0 100 ROERE Wiring diagram Alt roe aor 112 StS amp 9 SHS SES RES RENSE SL IKE RS ES REA S AE ES E AES E ES EE E Programming diagram Al1 TYPE LP1 PV Al1 OV LP1 TYPE AO1 INP LP1 OV AO1 TYPE LINEAR STD CAT LP1 FB AO1 BC 7 8 UDC5300 Controller User Manual 5 00 Using a Factory Configuration 7 4 2 Configuration 02 102 Heat Cool with Current Output for Each Des
169. alarm setpoint value LOW Low Alarms when input value lt alarm setpoint value DEV Deviation Alarms when input value deviates above or below compare point value by an amount gt alarm setpoint value HDEV High Deviation Alarms when input value deviates above compare point value by an amount gt alarm setpoint value LDEV Low Deviation Alarms when input value deviates below compare point value by an amount gt alarm setpoint value H RATE High Rate Alarms when input value increases at rate gt alarm setpoint value in input units per minute Negative rate setpoints are processed as positive values May take up to 30 seconds to activate L RATE Low Rate Alarms when input value decreases at rate gt setpoint value in input units per minute Negative rate setpoints are processed as positive values May take up to 30 seconds to activate 5 00 UDC5300 Controller User Manual 9 67 Using Program Mode to Configure Function Blocks and Features Table 9 31 Alarm Prompts Prompt Range Selections Definition Full name IDPT XX XXKX Input Decimal Position Move the decimal point to XXX XXX the position used by the input to the alarm function Input Decimal XXXX XX block Position XXXXX X XXXXXX INP OFF Input Specify the source of the value to be Input NUMBER monitored PARM analog NUMBER setpoint or enter a number here PARM analog lf a number is entered here the operator will be able to
170. amp Cable 1 225 53 Lithium Battery 1 1 5 00 UDC5300 Controller User Manual 22 5 Parts List Figure Detail Part Description Quantity 225 36 51404667 001 PROM Set U5 amp U22 1 21 51404654 501 Operating PROM Set Replacement Kit for units without Data Storage Capability 1 kitincludes Figure Detail Part Description Quantity 22 5 36 I51404654 001 PROM Set U5 amp U22 1 22 6 UDC5300 Controller User Manual 5 00 Parts List Exploded views PANEL MOUNTING SCREWS 46 KIT 17 Yea 12 PANEL MOUNT ONLY GASKET 48 KIT 17 PANEL MOUNTING T BARS 47 KIT 17 Figure 22 1 Instrument Panel Mounting Hardware 5 00 UDC5300 Controller User Manual 22 7 Parts List SUB BEZEL 2 KIT 1 ALUMINUM CASE 1 KIT 1 SHELL SEAL GASKET 44 KIT s 1 OR 19 ee FOUR SUB BEZEL SCREWS 25 KIT 1 UPPER AND LOWER PIVOT ARMS 49 KIT 5 PCMCIA CARD 54 KIT 15 COMPLETE DISPLAY ASSEMBLY MEMBRANE KEYPAD ONLY INCLUDES MEMBRANE KEYPAD 7 KIT 3 4 KIT 2 Figure 22 2 Instrument Card Cage Removed From Case along with Sub Bezel and Gasket 22 8 UDC5300 Controller User Manual 5 00 5 00 Parts List SHELL ASSEMBLY PART OF KIT 2 DISPLAY BOARD PART OF KIT 2 SWITCH CAPS 3 KIT 3 TWO RUBBER BUMPERS PART OF KIT 2 DISPLAY REAR COVER PART OF KIT 2 Figure 22 3 Explo
171. an change the setpoint using the keys on the front panel Rate is expressed in the block input s engineering units per minute Variable slew limits are available by programming CN constant blocks Destinations with IS increase slew and DS decrease slew See Programming Constants 9 9 Setpoint Low Limits SPHL Setpoint High Limits NUMBER Setpoint Low Limit and Setpoint High Limit Specify the limits to be imposed on the active setpoint value regardless of source A setpoint value below or above the limits will be entered into the loop at the applicable limit value OFF entry will assume process variable limits Variable limits are available by programming a CN constant block s Destination with LS or HS See Programming Constants Section 9 9 Input Engineering Units Input Engineering Units Units of measure Fahrenheit or Celsius for values of process variable or setpoint which will appear on online loop displays Note that the controller can display Rankine or Kelvin values If one of these are used select NONE Output Engineering Units Output Engineering Units Units of measure Fahrenheit or Celsius for block s output value Ratio Setpoint Enter initial ratio setpoint Value can be changed online 5 00 UDC5300 Controller User Manual Using Program Mode to Configure Function Blocks and Features Table 9 8 Loop Prompt Descriptions Prompt Applies Ran
172. and performance typically found in a controller much larger than its 1 4 DIN size The use of function blocks for configuration and a large variety of standard control algorithms allow the controller to satisfy the most demanding control applications The controller is available for one or two loops of independent or cascade control and offers a diversity of output types The optional Setpoint Profiler allows the configuration of a profile with up to sixteen ramp and soak segments for batch cycle operations An optional data storage feature allows real time storage of process data and operator actions as well as storage and recall of configuration calibration and setpoint profiles User interface 5 00 An easy to read display provides instant access to process values on operator displays Every live display includes a bargraph indicating deviation of process variable from setpoint In addition display indicators alert the operator to process alarm conditions loop selected setpoint selected Auto Manual status and setpoint profile status During programming you select which operator displays are used and their sequence MANUAL DISPLAY nro vas MENU SETPOINT RN lt i W ENTER Figure 1 1 UDC5300 Front Panel UDC5300 Controller User Manual 1 1 Introduction With three modes of operation Online Program and Maintenance the full range of setup operation and maintenance functions are
173. as three modes of operation Program Online and Maintenance Each mode has its own menus and prompts The SET MODE prompt is available in all three modes Use it to switch the controller from one mode to another Program mode Program mode is an offline mode for programming configuring the instrument In this mode all outputs are frozen Online mode Online mode enables full use of the instrument with its inputs outputs and internal programming In this mode it is fully interactive with all externally connected elements Maintenance mode Maintenance mode is an offline mode Functions include calibration offline diagnostic testing and various setups for operation In Maintenance mode all outputs are frozen 6 2 UDC5300 Controller User Manual 5 00 Modes Menus Prompts and Keypad Basics 6 2 2 Menu for Each Mode Overview Each mode of operation has its own menu of functions or programmable items Many of the top level items in these menus particularly in Program and Online mode have sub menus of functions or configurable parameters below this top level Figure 6 1 shows the main top level menu choices for each mode UDC 5300 ONLINE TUNE LOOP gt PROFILE gt SUMMARY gt DATAENT STORAGE Y lt PRETUNE lt REVIEW SET MODE ON LINE PRGRM gt SETMODE PRGM gt PRGAIL
174. ast value The input value is 1 measured normally when HOLD or the specified parameter has a value of 0 HOLD appears only if EXPINP is enabled under FEATURES on the Program Mode Menu Xn and Yn OFF X and Y Coordinates Define the custom curve to be X and Y NUMBER used by the input algorithm Interpolation is straight line Coordinates Xn Represents the incoming signal in the CKUN unit of measure Yn Represents the corresponding value in the TMPU unit of measure A minimum of two and a maximum of twenty points can be defined 5 00 UDC5300 Controller User Manual 9 11 Using Program Mode to Configure Function Blocks and Features 9 3 Programming Loop Blocks Control loop programming requires multiple blocks The controller can provide one or two loops of independent or cascade control Each loop has an associated loop LP loop function block Programming of the internal parameters for the LP block determines the control algorithm used as well as the tuning parameters and other custom values associated with the loop The LP block parameters are described in this subsection An LP block cannot function in isolation To perform control at least two more blocks are required one for input and one for output For example e Basic PID control using a Current Adjusting Type CAT or Voltage Adjusting Type VAT output would use an analog input AJ block to process the incoming process variable and
175. ation Follow the procedures and recommendations in this section to ensure a successful installation Consider the following items for each installation e Power line mains conditioning e Grounding for personal safety e Grounding for noise immunity e Suppression of noise from electrically connected loads e Suppression of noise from nearby not connected sources e Proper connections and terminations of communications links What s in this section 5 00 The following topics are covered in this section Topic Page 4 2 General Wiring Practices 4 2 4 3 Specific Instructions 4 4 UDC5300 Controller User Manual 4 1 Wiring 4 2 General Wiring Practices ATTENTION Wiring to be performed by qualified personnel only Mains power supply This controller is suitable for connection to 85 to 265 Vac 50 60 Hz power supply mains It is the user s responsibility to provide a switch or circuit breaker as part of the installation The switch or circuit breaker shall be located in close proximity to the controller within easy reach of the OPERATOR The switch or circuit breaker shall be marked as the disconnecting device for the controller Safety precautions An external disconnect switch is recommended for any hazardous voltage connections gt 30 V rms 42 4 Vpeak or 60 Vdc to the relay terminals Avoid damage to components CAUTION This equipment contains devices that can be damaged by electrostatic dischar
176. ation so that you can decide which if any is closest to your needs In addition this section will alert you to features you can enable disable before beginning programming This section stresses concepts underlying configuration of the UDC5300 Instructions for actually doing the programming are provided in later sections The end of this chapter tells you what to read next once you have decided whether to use a factory configuration or do freeform programming What s in this section 5 00 The following topics are covered in this section Topic Page 5 2 Function Block Capabilities 5 2 5 3 Factory Configuration Basics 5 23 5 4 Factory Configuration Applications 5 24 5 5 Tasks That Precede Programming 5 36 5 6 Where To Go From Here 5 37 UDC5300 Controller User Manual 5 1 Planning 5 2 Function Block Capabilities 5 2 1 What a Function Block Is Definition A function block is a software object that performs a piece of a control strategy such as processing an analog input or calculating a value A function block can be thought of as a black box that takes data in one end does something to the data inside the box and at the other end makes the data available to other function blocks Internal parameters influence operation How a function block does its job depends on the values programmed for the block s internal parameters For example a loop function block has a parameter t
177. average At the end of the time interval the output CVn OV steps to the value of the peak and holds this value until the next time interval has elapsed If the Reset Input RST turns ON the output is held and the time interval restarts CV pick picking prompts Table 9 17 describes the Peak Picking prompts Table 9 17 CV Peak Picking Prompts Prompt Range Selections Definition Full name ODPT XX XXXXK Output Decimal Position Move the decimal point to Doema XXX XXX the position to be used in the output value provided by Output Decimal XXXX XX the CV block Position XXXXX X XXXXXX INP OFF Input Source Specify the source of the input to the INPUT NUMBER CV function block PARM analog OTEU OFF Output Engineering Units Specify the unit of Output E measure Fahrenheit or Celsius for the output Engineering Units C RST OFF Reset Input A logical high 1 entered here or read R i 1 from the selected parameter causes the output of the Reset Input CV function block to be held and the time interval to be 0 reset to the beginning MIN OFF Minutes Specify the duration of the time interval Minutes NUMBER Action MAX rate matches the scan frequency see 9 15 AVG Maximum value reached by input during period STDDEV Averages input values during time period MIN Standard Deviation of the input value during period Minimum value of input during time period 5 00 UDC5300 Controller User Manual 9 39 Usi
178. aves changes made and returns to higher menu if pressed when prompted to save changes Figure 14 1 Example Of A Primary Display If a value is flashing either the value is clamped at its output limit or in the case of a totalizer or interval timer value the value is outside its limits but not clamped If a value alternates with a string of asterisks either the relevant Al is an open circuit with failsafe or the AI is linear and is outside the programmed range by 10 or more UDC5300 Controller User Manual 14 3 Using Primary Displays to View Process Values and Change Setpoints Available displays The displays actually available to an operator and the sequence in which the displays are presented is configurable using PRG DPYS from the Program menu Table 14 1 lists all the possible displays Table 14 1 Primary Displays Displayed Function Values PV Allows online changes to working setpoint while viewing Working SP read only PV Note that your attempts to change the working setpoint will be unsuccessful if it is clamped at the setpoint high or low limit for the loop PV Allows online changes to loop output while viewing read Loop Output only PV for types other than ON OFF PV Read only PV and state of ON OFF type loop only ON OFF Loop Output State PV Read only PV and deviation of PV from setpoint DV PV Allows online changes to ratio setpoint while viewing read Ratio Setpoint only PV PV Read
179. ays displayed Operator display formats vary In Online mode some displays follow this same value over prompt format These are the displays used with the Online menu In Online mode operator displays are also available that 6 10 UDC5300 Controller User Manual 5 00 Modes Menus Prompts and Keypad Basics show process values alarm status etc Operations performed with Online mode menus are described in Section 15 Online mode operator displays are described in Section 14 6 3 2 3 Using the Cursor Significance of location The three small lines to the right of AI1 TYPE in the example above are the cursor Because it is positioned next to the prompt we know that this prompt has not yet been selected for editing Moving the cursor Pressing the ENTER key would select the parameter for editing The cursor would change shape and move up next to the value like this LINEAR Al1 TYPE Once you have cycled through the choices or editing a number as described below and pressed ENTER the cursor will move back down next to the prompt Use the INCREMENT A or DECREMENT VW key to move on to the next item to be configured 5 00 UDC5300 Controller User Manual 6 11 Modes Menus Prompts and Keypad Basics 6 3 2 4 Viewing and Changing Values Viewing valid selections Once a prompt has been selected for editing the valid choices available can be displayed using the INCREMENT A and DECREMENT keys to
180. basics Regardless of how you plan to program your controller if this is the first time you have used a UDC5300 controller read Section 6 It contains basic information about using the controller s user interface All subsequent sections assume that you know the basic ideas and terminology presented in Section 6 Using a factory configuration If you decide to use a factory configuration and have not configured a UDC5300 before then after reading Section 6 go to Section 7 That section includes instructions for loading and customizing factory configurations After implementing your control strategy read Subsection 9 8 to learn how to configure process alarms If you want to require use of a password to restrict access to the controller s database read Subsection 9 13 to learn how to define passwords and specify what functions require their use Finally read Subsection 9 11 to learn how to specify which displays are available to the operator and their sequence Freeform programming If you have decided to do freeform programming and have not configured a UDC5300 controller before then after reading Section 6 move on to Section 8 That section provides a demonstration of function block programming basics It tells you how to approach the task and what to do to implement your strategy Every function block type is described in Section 9 For each type the description includes the prompts in the order displayed the purpose of each
181. ble 10 2 Procedure for Calibrating the PP Output 1 After the controller is wired to the drive unit according to the instructions in Section 4 place the controller in Online mode briefly before proceeding with the feedback calibration The following procedure calibrates the feedback slidewire input to achieve 0 to 100 of the actuator travel 3 Select the AO being used for the loop output In the case of our example it would be CALIB AO3 LOW Press ENTER The decrease output relay will energize to drive the motor to near 0 output Use the DECREMENT or INCREMENT A key to place the drive unit at the desired low end position while watching motor position in percent on the display Press ENTER to establish the 0 position of the motor 4 Select CALIB AO3 HIGH Press ENTER The increase output relay will energize to drive the motor to near 100 output Use the W or A key to place the drive unit at the desired high end position while watching motor position in percent on the display Press ENTER to establish the 100 position of the motor 6 Go to Online mode and with the control loop in manual increase and decrease the control loop output and verify proper actuator operation before placing the loop into automatic control 5 00 UDC5300 Controller User Manual 10 7 Position Proportioning Output Setup and Calibration 10 8 UDC5300 Controller User Manual 5 00 Configuring and Using Setpoint Profiler 11 Configuring and Usi
182. ble 21 1 shows messages that may appear on the controller displays if a diagnostic condition is detected along with the action you should take Table 21 1 Diagnostic Messages INPUT FAILUREnn Other results of input problems are described on the next page 1 Number nn analog input wiring to instrument has opened or shorted 2 The analog inputs have been exposed to electromagnetic noise 3 The electrical signals to the instrument s analog inputs have gone above or below the input s measurable range The measurable range will be determined by the input s gain setting or short 2 Shield the inputs 3 See Note 1 below Instructions for clearing the message are provided on the 1 Check input devices for open next page FLOAT PT ERROR A floating point calculation error has occurred divide by zero underflow overflow Math CV inputs for division by 0 Also check for input values producing a underflow or overflow error that is calculation is not between 1x10 and 3x10 or not between 1x10 Check Free Form Math and and 3x10 An error was detected in the database of one or more function blocks The affected function blocks are reset to their defaults configuration and reconfigure as Inspect entire instrument needed Manual and Manual to Auto If failure continues check the Cycle the controller Auto to integrity of slidewire input Note 1 When an
183. cess the forcing choices Adjust with the A and W keys Press MENU to leave the menu Note that when the programmed label for a DI or DO is on display the F that usually indicates Fahrenheit see Figure 14 1 will be lit if the current value of the DI or DO is the result of its having been forced to that state 5 00 UDC5300 Controller User Manual 15 11 Using Online Menu Functions Table 15 8 Data Entry Prompts Prompt Range Selections Explanation Full name AIADJ Select an Al to adjust Use this function to Al Adjust e adjust the gain applied to the input from a Spectray or Rayotube pyrometer emissivity adjustment to compensate for the color of the objects on which the pyrometer is sighting or e to adjust the bias zero if the input comes from a thermocouple First use a reference device to determine the actual temperature the input should represent Next when the AIADJ prompt is on display press ENTER to display the current Al value Use the A and W keys to make the displayed value match the actual temperature Press ENTER and the controller will adjust the gain or bias accordingly SET AO Select an AO to adjust Use this function to tune Analog Output parameters See Table 15 10 Changing Alarm Setpoints Online If an alarm setpoint was configured in Program mode as a number not read from another parameter the value of the alarm setpoint can be changed online using the procedure in T
184. ch scan cycle the input value is added to the running total When total reaches or exceeds PSET the discrete output of the CV goes to 1 and remains 1 for one scan cycle The totalizer then resets and starts again The value resets to either zero or the residual total The residual total is the final total minus the preset value that is the value that accumulated during the one scan cycle that it takes the totalizer to reset DOWN Down Each scan cycle the input value is subtracted from the PSET value When this result reaches or goes below zero the discrete output of the CV goes to 1 and remains 1 for one scan cycle The totalizer then resets and starts again The value resets to either PSET or the residual total The residual total is preset plus final total since final total is either zero or negative DEMD On Demand Same as UP except input is added only while the ENAB discrete has a value of 1 Input is ignored while ENAB is 0 CONT Continuous Same as UP except the total ignores the PSET value and increments to the maximum value 999 999 999 then resets to 0 and continues PSET OFF Preset Output Value Specify the value or its source ACTN Action Select the totalizer action Note that the NUMBER When the RST goes high 1 an UP action totalizer will reset to zero or a DOWN action totalizer will reset to PARM analog the preset value RST OFF RST Specify the parameter to s
185. cing with the DO blocks FB2 AO4 BC associated with the relays used for DAT output OVDB nn If appropriate enter a control deadband RNGL nnn Specify the range limits for display The output is not clamped nor will it flash on the display when it is outside this range RNGH nnn AO blocks to interface between the splitter and the relays DAT output requires two AO blocks to serve as the interface between the splitter and the DO blocks associated with the relays wired to the controlled devices These AO blocks are not associated with any analog output hardware Table 12 13 and Table 12 14 show the programming for the AO blocks used for this purpose Note that the block also has other internal parameters that should be configured such as the minimum on and off times appropriate for the devices being controlled slew limits a failsafe value if enabled etc See Section 9 for the complete list of DAT type AO parameters Figure 12 1 Table 12 13 AO3 Configuration for DAT Output AO3 Programming Notes TYPE DAT Our example uses time proportioned output IDPT XXXXX X Set to match the CV3 ODPT INP CV3 A1 When LP1 PV is less than its setpoint the splitter will use its A1 output OUT DO1 The device enriching the carburizing gas should be wired to the terminals for DO1 Note that once DO1 has been assigned to work with AO3 the DO1 input and action cannot be progra
186. cription This PID loop with split output provides a current output to one actuator when the process variable is above setpoint and to another when the PV is below setpoint A control deadband is configurable Although it is titled heat cool it can be used for other applications The split output is achieved with a calculated value CV function block programmed to be a standard splitter Basic diagram PV Wiring diagram Programming Diagram Al1 TYPE LINEAR 5 00 Analog HEAT Output 1 pe 4 20 mA Analog Input 1 ot FS ee Analog 0 100 j j COOL X Output 2 s 4 20 mA Ali AO2 j j Bie BOs K VER FADE Sal LOHAN L1 A ES L2 N SE IR i ee ES Slm EGS S OAO AI S A AO1 TYPE AO1 INP CAT CV1 A1 CV9 FBI AO1BC LP1 PV LP1 TYPE CV9 INP k AO2 TYPE Alt OV SPLIT LP1 OV AO2 INP CAT i CV9 A2 4 CV9 FB2 AO2 BC LP1 FB CV9 BC UDC5300 Controller User Manual 7 9 Using a Factory Configuration 7 4 3 Configuration 03 103 Heat Cool with Current Out for Heat and Time Proportioned Relay for Cool Description This PID loop with split output provides a current output to one actuator when the process variable is above setpoint and a time proportioned relay output to a different actuator when the PV is
187. ction Read the warning and other information on this page before changing the switch settings for an analog input WARNING This procedure should be performed by qualified personnel only lt is not necessary to remove power before using the button below the front panel to release the bezel latch nor before lifting the bezel out of the way on its bail linkages to access the PCMCIA card used to store data However disconnect power before using a tool to open the latches on the plate uncovered when the bezel is lifted out of the way Opening these latches provides access to the instrument assembly which slides out of the case A potentially lethal shock hazard exists if the instrument assembly is accessed while powered More than one switch may be required to disconnect power ATTENTION This equipment contains devices that can be damaged by electrostatic discharge ESD As solid state technology advances and as solid state devices get smaller they become increasingly sensitive to ESD The damage incurred may not cause the device to fail completely but may cause early failure Therefore it is imperative that assemblies containing static sensitive devices be carried in conductive plastic bags When adjusting or performing any work on such assemblies grounded work stations and wrist straps must be used If soldering irons are used they must also be grounded A grounded work station is any conductive or metallic surface connected to an
188. ction 9 4 Select PRG DO on the Main Program Menu Select a DO to program Discrete output prompts Table 9 15 describes the Discrete Output prompts Table 9 15 Discrete Output Prompts Prompt Range Selections Definition Full name Action State Specify whether the input will be normally closed or normally open when ON NORMAL Normal Closed when ON not inverted INVERT Invert Closed when OFF INP OFF Input Specify the source of the input to the DO function block or enter a value of 0 or 1 here Input source 1 0 PARM discrete ONL See Table 9 14 On Label and Off Label Select the labels to be used On Label inthe Summary display and by optional data storage On Label feature when the discrete output is ON value 1 and and OFF value 0 OFFL Off Label 5 00 UDC5300 Controller User Manual 9 37 Using Program Mode to Configure Function Blocks and Features 9 7 Programming Calculated Values A Calculated Value CV block provides an output value derived from calculations involving values read from other blocks including other CV blocks The calculations can be mathematical or logical operations and the CV output can be analog or discrete Once a CV is created it can be used by any function block as many times as necessary ATTENTION If you plan to program another function block to use a Calculated Value you must program the Calculated Value first Up to sixteen Calculated Values can be p
189. ction Blocks and Features Table 9 3 Analog Input Types Display Symbol Type Operating Span 998814 18899 8814 340 to 1800 172 to 982 940579 18894 0579 752 to 2552 400 to 1400 949014 18894 9014 752 to 2552 400 to 1400 188861 Spectray 18886 1 1292 to 2912 700 to 1600 18886 Spectray 18886 1833 to 3452 1001 to 1900 188852 Spectray 18885 2 806 to 1400 430 to 760 188851 Spectray 18885 1 1292 to 2912 700 to 1600 18885 Spectray 18885 1832 to 3452 1000 to 1900 750579 18875 0579 752 to 2552 400 to 1400 740578 18874 0578 752 to 2552 400 to 1400 IPTS 68 9 8 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Custom analog input algorithm prompts Table 9 4 describes the custom analog input algorithm prompts These prompts are displayed if CUSTOM is selected in response to the ALGR prompt Table 9 4 Custom Al Algorithm Prompts Prompt Range Selections Definition Full Name SIG Signal Specifies the input hardware type Signal OFF TC Thermocouple EMF Electromotive Force RTD Resistance Temperature Detector IDPT XX XXXXK Input Decimal Position Move the decimal point to the i Begina XXX XXX position to be used in the input value provided to the Al Input Decimal XXXX XX function block Position XXXXX X XXXXXX ODPT XX XXXX Output Decimal Position Move the deci
190. ction between condition types and Table 9 21 illustrates the interaction between the condition type and the condition time 5 00 UDC5300 Controller User Manual 9 47 Using Program Mode to Configure Function Blocks and Features Table 9 21 CV Condition Time and Condition Type Prompts Condition type Application If this is true then CVn OS is NONE R Result Result SSS a Condition type Application If this is true then CVn OS is DELAY Filters short pulses Result switches ON 1 forn ON n seconds minus Delays rising edge of Result seconds gt CONDITION CONDITION TIME for CONDITION TIME TIME Condition Type Delay Condition Time 3 seconds If Result is On at least least 3 sec Then CVn OS is EXTEND slower circuits seconds then OFF 0 plus CONDITION Po gt oioi0s O TIME then OF F O Extends falling edge of Result switches ON 1 ON with no delay Used for interfacing with Result switches ON 1 forn ON 1 for n seconds Result for CONDITION Condition Type Extend Condition Time 3 seconds If Result is Then CVn OS is ec extend ec extend Time 9 48 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 21 CV Condition Time and Condition Type Prompts Condition type Application If
191. cycle through the list Valid values or selections fall into three categories e strings of characters representing choices in a list such as the types of analog input types e anumber such as the range high and range low limits for an analog input e aparameter in another function block such as the source of the process variable PV used by a loop LP function block The following paragraphs describe how each type of value or selection is edited Selecting a text string When the prompt requires that you select an item from a list such as the AI1 type in our example simply use the INCREMENT A and DECREMENT F keys to cycle through the list When the one you want is displayed press ENTER The item will be selected and the cursor will move back down next to the prompt Use the DECREMENT VW key to go on to the next parameter Editing a number If the prompt requires that you enter a number use the procedure in Table 6 1 to enter the number Note that sometimes the valid responses to a prompt include either entering a number or selecting OFF In this case use the INCREMENT A and DECREMENT F keys to display your choice of OFF or NUMBER Press ENTER to make your selection If your choice is OFF indicating that the parameter will not be used then the edit is complete and the cursor will move back down next to the prompt You are ready to use the DECREMENT VW key to go on to the next parameter If you
192. d condition to control excessive overshoot when setpoint is reached Approach Low Value entered affects the process variable approach to setpoint when the process variable value is greater than the setpoint value Setpoint Tracking When SP2 is selected setpoint tracking is enabled This means that when control action begins to use Setpoint 2 the value of Setpoint 2 is copied to Setpoint 1 Adjustment of Setpoint 1 may be made after the switchover Setpoint 1 Setpoint 1 and Setpoint 2 are independent setpoints Either may be the active setpoint for the loop Enter the value to be used as the initial setpoint This can be changed online 5 00 Prompt Full name To Using Program Mode to Configure Function Blocks and Features Table 9 8 Loop Prompt Descriptions Setpoint 2 NUMBER PARM analog Setpoint 2 Enter the value to be used as the setpoint or use the PARM selection to specify the function block whose output value will serve as the source of the PV When Setpoint 2 is specified as an analog parameter the value may not be changed from the front panel To use an output value from a CN function block select PARM If you are using the setpoint profiler option set SPT2 to the setpoint profiler block s output value SP1 OV Increasing Slew Limit DSLW Decreasing Slew Limit NUMBER Increasing Slew Limit and Decreasing Slew Limit Specify limits for rate at which operator c
193. d for each set of tuning parameters Gain ees depends on the setting entered for GNPB in Program or range is 0 1 to 200 for mode Enter the proportional component to be applied PBI Gain by the control algorithm SE 1000 0 If an indirect source was specified during Proportional 3 oad programming the value can only be altered at the Band or Proportional Band source not here in Online mode many times proportional action should be repeated per Reset NUMBER minute This is the integral component of control Sa 0 005 lo 99 99 Reset adjusts the controller s output taking into repeats per minute consideration both the size of the deviation SP PV and the duration of the deviation The amount of corrective action depends on the value of PB1 or GAIN1 To allow proportional only control select OFF When reset is turned off the MRST manual reset value determines the loop output at setpoint Bumpless manual to automatic transfer is cancelled when proportional only control is selected RTE1 RTE2 OFF Rate 1 and Rate 2 Enter the time period to be used by the derivative component of control which affects Rate NUMBER the loop s output whenever the deviation between range is 0 02 10 00 setpoint and process variable is changing The output minutes will be affected more when the deviation is changing faster The output is modified by a value that assumes the rate of change of the process variable will continue
194. d into accurate output signals The feedback path that provides LP1 with this confirmation is established by means of program settings depicted in Figure 8 6 TYPE J THERMOCOUPLE 470 20 mA INPUT TYP E J W 0 RANGE HIGH 1 000 TYPE STANDARD OUTPUT TYPE CAT 0 SP1 500 IN LOW LIMIT GAIN 10 IN HIGH LIMIT 100 RESET 1 OUT LOW LIMIT 4 RATE 0 OUT HIGH LIMIT 20 Figure 8 6 Complete Function Block Diagram of Figure 8 1 Here the function block diagram is drawn to include the key components of a typical loop feedback path The AOI function block has been changed to feature a second output denoted AOI BC This output has been connected to a feedback input at LP1 identified by the notation FB The AOI BC designator stands for Analog Output 1 s Back Calculation When the control loop is brought on line AO1 BC will essentially represent the value of AOI s 4 mA to 20 mA output at any particular instant The term Back Calculation is used to reinforce the idea that this information is being sent upstream against the flow of all other information within the function block diagram UDC5300 Controller User Manual 5 00 Learning to Create Custom Programs 8 3 Time Proportioning Relay Driven Pump Introduction A second control scheme is to use a relay to produce a time proportioning or Duration Adjusting Type DAT control signal Such an application is depicted in Figure 8 7 L
195. d when proportional only control is selected RTE1 all OFF Rate 1 Enter the time period to be used by the NUMBER derivative component of control which affects the loop s output whenever the deviation between except range is 0 02 10 00 setpoint and process variable is changing The ON_OFF minutes output will be affected more when the deviation is changing faster The output is modified by a value that assumes the rate of change of the process variable will continue for the time period specified using this prompt first set of tuning parameters Enter a starting value or OFF at the time of configuration The value may be altered online for final loop tuning Variable rate1 is available by programming a CN constant block s Destination with RT See Programming Constants Section 9 9 9 18 UC5300 Controller User Manual 5 00 Prompt Full name or PB2 Proportional Band 2 Reset 2 5 00 Applies To Using Program Mode to Configure Function Blocks and Features Table 9 8 Loop Prompt Descriptions NUMBER range is 0 1 to 200 for Gain or 0 5 to 1000 0 for Proportional Band NUMBER range is 0 005 to 99 99 repeats per minute NUMBER range is 0 02 to 10 00 minutes Gain 2 or PB2 Which prompt is displayed depends on the setting of GNPB Enter the proportional component to be applied by the control algorithm in the second set of tuning parameters Use of the second set of tun
196. dct Mislead ey rand trade De See een dr 17 3 Tabler DS SEFU PIPE RO ES cect se honest e bats onulaaaasandiacdsaneiceienan 17 4 Table TA SE F RND Prom pis a odense east enna tte ker raat Nice Slants Aal elb se Tun ens st eee 17 4 RE eo S SES AN cil ay a4 sy D PrOD Eea ene teen nee nena te eaten enn tee meter tentenr ant a tent net arty iene eran e etter 17 6 Table 17 6 Memory Card Capacities for Trend Data When AED Storage is Enabled 0000000000000 17 8 Table 17 7 Memory Card Capacities for Trend Data When AED Storage is Disabled 0 17 9 Fable 177 8 Rollover enabled MMU sssr E ue akser DSN etna utade 17 11 Table t79 Rollover Disabled Me Has ease habialasastnceasnasrateeteateetenea E 17 12 Table TlO DAS fora se MESSI Ce no a a idet Vda usa aaa 17 13 Table 18 1 Sera Communications PromplS asire ienaa e Ee E N ea 18 2 Table ts Terminato Procedure ei ENE 18 4 Table 19 1 Analog Input Calibration Procedure for EMP or Thermocouple Inputs eee 19 3 Table 19 2 Analog Input Calibration Procedure for RTD Inputs 20 0 cc ccccccccccccceecceeeeeeeeeeeeeeeeees 19 4 Table 19 3 Analos Output Calibration Procedure eisson anse here tabesls 19 6 Table 20 ls SI TOTP Site RS ETAS SE erat E elena ta dees at cada tnt stellet lene seet skt es 20 2 Table 20 2 Procedure for Accessing the DIP SwWitCheS ass enke AG bh helle sandede 20 4 Fable 271 Diasnosic Messa ESen E Pn Ee nm Ebbesen nT oe 21 2 Table 21 2 Internal Fa
197. ddition for the strategy to work as intended it is essential that I O wiring be installed at the terminals matching the use of I O function block types in the factory configuration A wiring diagram for each strategy is provided later in this section If none of the strategies exactly match your requirements start with the factory configuration that is closest to your needs Once it is loaded modify it to suit your application by changing I O types changing control action or other essentials CUSTOMIZATION If desired you can further customize the strategy by adding functionality with additional blocks For example it is easy to add alarms or a totalizer type calculated value CV block UDC5300 Controller User Manual 7 3 Using a Factory Configuration 7 3 1 Necessary Configuration Ranges Factory configurations preset the controller ranges for 0 to 100 If these are not suitable for your application change them Analog inputs Factory configurations set all analog inputs to INDIRECT type with 1 V to 5 V input span Modify as needed All analog inputs have their type set to LINEAR Specify the proper analog input type and range for each input If the input is a direct sensor such as a thermocouple start by changing the D ID parameter from INDIRECT to DIRECT then select the sensor type range limits and other desired actions If the input is from a flow transmitter requiring square root change the D ID from INDIR
198. de position proportioning output Loop 2 uses two relays to provide direction impulse adjusting output An analog output AO block with both its type and its positioning algorithm set to PP position proportioning interfaces between the Loop LP1 block and the discrete output DO blocks associated with the PP increase and decrease relays An analog output AO block with its type set to PP position proportioning and its positioning algorithm set to DIAT interfaces between the Loop 2 LP2 block and the discrete output DO blocks associated with the DIAT increase and decrease relays In this application the AO block is not associated with analog output terminals Loop 1 uses an analog feedback signal from the positioner s slidewire received at AI2 The feedback is powered by a constant 1 V from the terminals associated with AOI and its VAT voltage adjusting type AO function block having an output range from 0 to 5 Because the input to the AO is 20 from a constant CN block a steady 1 V out is achieved 20 of the 5 V range Basic diagram 7 54 INC Analog Input 1 Relay 1 PID PV Loop1 0 100 DEC Relay 2 Position Proportioning Analog Input 2 Slidewire D Feedback Analog ee Output 1 1 V Power for Slidewire Feedback INC Analog Input 3 Relay 3 PID PV Loop2 0 100 i DEC Relay 4 DIAT UDC5300 Controller User Manual 5 00
199. ded View of Instrument s Display UDC5300 Controller User Manual 22 9 Parts List GROUND BUS BAR 24 KIT s 1 or 18 REFERENCE Ss N JUNCTION bag BUSHING A 5 KIT 1 E GROUND WIRE y we 49 KIT 18 CA CASE REAR T cable COVER RETAINER 6 KIT 1 TIES 7 KIT 4 gt KIT 19 THIS CONNECTION ESTABLISHED VIA DETAIL 24 TERMINAL BLOCK RS 8 KIT s 1 10 13 14 or 19 FERRITE CLAMP 51 KIT 19 a VA HINA ES ord TT Bury COVER PLATE 43 KIT s 1 or 19 oe SUPPRESSION ASSEMBLY 50 KIT s 13 14 or 18 Figure 22 4 Components of Instrument Rear Assembly 22 10 UDC5300 Controller User Manual 5 00 Parts List 2 RELAY OUTPUTS 2 DISCRETE INPUTS PCA UPPER REAR OR SUPPORT CAT OUTPUT THREE DISCRETE INPUTS PCA MOLDING SINGLE SCIEN FIRS APRUT PCA 30 KIT s 13 or 14 10 KIT 19 OR POWER SUPPLY THREE TC EMF RTD INPUTS PCA WITH TWO RELAY 28 KIT s 7 or 8 OUTPUTS BOARD 4 29 KIT 9 N RS 485 SERIAL COMMUNICATIONS PCA MODULE 32 KIT 10 5 16 PLASTIC STANDOFF USE QTY 4 TO MOUNT SERIAL COMMUNICATIONS MODULE TO COMMUNICATIONS POSITION 1 BOARD PROM 33 KIT 10 34 KIT 10 GE Bien 27 KIT 6 a ee PCMCIA MEMORY CARD INTERFACE OR PLATE USED ONLY IN UNITS WITHOUT MEMORY CARD padai re PROTECTOR 26 KIT 16 PC MOLDING 14 KIT 4 LOWER REAR SUPPORT
200. designations Connect analog output leads to the appropriate terminals for analog outputs in card slot 1 or 3 Figure 4 4 and Figure 4 6 Analog outputs may be current or voltage types Maximum load resistance for current outputs is 800 ohms Minimum load resistance for voltage outputs is 1000 ohms PP output connections Position Proportional PP type outputs require two analog inputs two discrete outputs and one analog output Figure 4 8 The analog output must be a voltage type VAT programmed to provided a constant I V to power the slidewire feedback See Section 10 for sample PP feedback configuration Alt id aor IT ER LOT ILS 7 i Serena EN L1 Actuator A E L2 N Voltage SORIS Ss SEE S S S DOU INC Al2 gt DEC Figure 4 8 PP Typical Wiring 5 00 UDC5300 Controller User Manual 4 13 Wiring DIAT connections Motor Direction Control DIAT requires two discrete outputs Figure 4 9 L1 L2 N DO1 NO DO1 C DO1 NC DO2 C DO2 NO ollaa g Direction Impulse Adj Type DIAT Figure 4 9 DIAT Typical Wiring DAT connections DAT output types use any discrete output relay Up to four DAT type outputs may be assigned to a single loop Figure 4 10 gJ K 25 D L1 L2 N DO1 NO DO1 C DO1 NC DO2 C DO2 NO
201. display will show STORE CFG gt MOD press ENTER The display will change to show the name of the first file on the card 4 Press the DECREMENT VW key to cycle down to LOAD CFG gt UDC and Remember that the card can also contain setpoint profile files 5 To select a different file press the DECREMENT VF key until the desired file s name is displayed 6 To initiate the load operation press ENTER display reads LOAD COMPLETE you can press MENU to exit the function 7 During the storing operation the display will read FILE LOADING When the Remove the card or go on to Step 8 to load the calibration 8 To load the calibration also press MENU until LOAD CFG gt UDC is again displayed then press V LOAD CAL gt UDC will be displayed 9 Press ENTER to select this function The display will change to show the name of the first file on the card 10 Repeat Steps 5 through 7 to load the calibration file 11 Press MENU to exit the function 12 Remove the card UDC5300 Controller User Manual 16 5 Storing and Loading Configuration and Calibration 16 6 UDC5300 Controller User Manual 5 00 Storing Data 17 Storing Data 17 1 Introduction Overview The optional data storage interface enables you store process data alarm event and diagnostic information on a portable PCMCIA card Personal Computer Memory Card International Association for
202. displays a descriptive error message For example if you try to program a function block incorrectly the controller tells you the problem ATTENTION Displayed messages such as error messages displayed after a factory configuration is loaded can be followed by anumber That number is not an error code number The number identifies the line in the file where the error occurred Table 21 4 lists these error messages alphabetically along with a description of each one and what action to take Table 21 4 Error Messages Error Description User Action Channel Does Not A channel was loaded that does not exist For Re program or re load Exist example you loaded Al3 but your unit is only correctly equipped with Al1 Circuit Limits Equal Indirect circuit low circuit high limits must be Change to unequal limits unequal Condition Type Out of Internal Error Range Deviation Limit Must Setpoint Profiler Deviation Low Limit and Change limit be Positive Deviation High Limit must be positive Drive Unit Speed Less For PP type analog outputs the drive unit Increase drive unit speed to than or Equal to 0 speed should be greater than 0 greater than 0 circuit mV specified limits for that type Table 9 3 High Output Limit Greater than 20 High Output Limit Greater Than 5 than 5 Hysteresis Less Than Alarm Hysteresis parameter should be greater Change Hysteresis High Limit Outside of Al
203. e if the value of ASEL is 3 then INP3 signal is selected If the value of ASEL lt 1 then INP1 is selected The value of ASEL is truncated For example if the value is 3 55 the value used is 3 and INP3 is selected DIS SW Discrete Switch selects the input signal on the basis of the value of a discrete parameter DSEL INP1 is selected when DSEL has a value of zero INP2 is selected when DSEL has a value of one INP3 through INP8 are not used ASEL OFF Analog Switch If the action selected is ANA SW then this prompt is available Use it to specify the Analog Switch NUMBER source of the value used by the analog switch action PARM analog DSEL OFF Discrete Switch If the action selected is DIS SW then this prompt is available Use it to specify the Disercie witch NANE E source of the value used by the discrete switch action PARM discrete 9 42 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 7 3 CV Math Operator MATH Introduction The math operation performs math on up to eight input values using a single operator The result is used as CVn OV Division by 0 indicated by flashing 0 on primary display showing CV value ATTENTION The controller also supports a function block configured to perform a freeform equation of up to 32 characters Use Honeywell SCF configurat
204. e 9 3 Low Output Limit less A CAT or VAT low limit is less than zero Change CAT or VAT low limit than Zero to greater than or equal to zero Must have at least Setpoint Profiler was programmed with no Program Setpoint Profiler with one Step steps at least one step No Room for Function System has used all allocated function blocks Block Number of Frames Rolling Average CV of Samples is less than Change of Samples to 1 60 Out of Range 1 or greater than 60 Out of RAM Memory No more RAM available No user action Out of EEPROM No more static memory or EEPROM memory No user action Memory Output Limits Equal Output range limits low and high must be Change to unequal limits unequal Pairs Inconsistent Al is custom type and curve has Xn but no Yn Program a Y for each X or or vice versa Al is custom type but curve vice versa Program at least 2 does not have at least 2 X s and 2 Y s Profile Data Setpoint Profiler contains a step time and step Correct inconsistency Inconsistent value that are not both OFF or that are not both a value RJ Not in Curve Al is custom type class thermocouple RJ Y values must contain 0 65 enabled but curve does not contain 0 65 degrees C 32 149 degrees degrees C 32 149 degrees F F Request Made with Invalid tag has been made in a request No user action Invalid Tag Requires Setpoint Alarm does not contain a setpoint Program alarm with a
205. e PV A second value can also be seen setpoint output value PID or status ON OFF ratio setpoint a calculated value a CN constant block s output A display is available for quickly switching between setpoints for the selected loop Display indicators for key system functions The display indicators shown in Figure 1 2 alert the operator to process alarm conditions loop selected setpoint selected Auto Manual status and setpoint profile status Any process values on display pertain to the loop indicated Online menus provide quick access to tuning parameters alarm setpoints and datapoint values The Online menus provide quick access to summaries of alarm setpoints values of all analog and discrete data points most recent diagnostic failure messages and other information Unless programmed to lockout the operator tuning parameters can be viewed and changed alarm setpoints altered and constants and other discrete parameters turned on and off Basics of mode menu and keypad use are provided in Section 6 Operator displays are described in Section 14 1 6 UDC5300 Controller User Manual 5 00 Introduction Upper Display six characters Value of selection indicated Lower Display eight characters Value as setpoint or output Degrees being used Controller mode Fahrenheit or Centigrade Manual or Automatic Active Loop 1 or 2 12 FC MAN Alarm condition ALM 1234 exists 5300 Bargraph Setpoint shows 12 SP
206. e and ratio value Pressing DECREMENT and INCREMENT A keys increases or decreases the ratio value The LEFT lt 4 key can be used to select a digit to change The following conditions apply 1 Only numerically assigned ratio values can be changed online Ratio value must not have been programmed as an analog parameter 2 The currently active setpoint must be SP2 14 6 UDC5300 Controller User Manual 5 00 Using Online Menu Functions 15 Using Online Menu Functions 15 1 Introduction Overview This section describes the use of Online menu functions These menus are accessed and values entered or selected as described in Section 6 Modes Menus Prompts and Keypad Basics It you are not familiar with the contents of that section review it before using the Online menus The tasks described in this section are e tuning a loop pre tuning the loop before the controller is brought online is described in Section 13 e viewing displays in the summary group alarms diagnostics I O points current time and date product information including firmware version e data entry e adjusting analog outputs e reviewing read only the values of function block parameters and other Program mode functions Other functions accomplished with the Online menu are described in other sections e setting up storing loading and using a setpoint profile Section 11 e storing data Section 17 Use of primary operator displa
207. e factory configuration to work as expected For your convenience a wiring diagram for each factory configuration is provided in Section 7 WARNING The diagrams in Section 7 are intended to supplement not replace the instructions in this section Be sure to read and understand this section before attempting to connect power or signal wires Turn power off at mains before installing AC power wiring TB 1 If model selection from Table IV is 0 No Communications gerade 00 TB 1 CONN 1 AO1 A 2 AO1 A 3 4 5 6 7 8 Slot 1 Not j Used TB 1 If model selection from Table IV is C Serial Comm Option TB 1 ceed UDC5300 Controller User Manual 00 Figure 4 2 Slot 1 Terminal Connections CO NI OORA WwW IN L Connect to TB4 terminal 25 for Earth Ground 5 00 Wiring
208. e input parameter CV inverter prompts Table 9 27 describes the Inverter prompts Table 9 27 CV Inverter Prompts Prompt Range Selections Definition Full name INP OFF Input Specify the parameter whose value will be INPUT inverted or enter a discrete value directly here PARM discrete ONL See Table 9 14 On Label and Off Label Select the labels to be used in the Summary display and by optional data storage On Label feature when the output is ON value 1 and OFF ana value 0 OFFL Off Label 9 58 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 7 9 CV Standard Splitter Output SPLT S Introduction This operation divides a Split loop s output 100 to 100 into two outputs CVn Al and CVn A2 both of which are zero when the loop output is zero Figure 9 2 A deadband can be defined When the loop output is within the deadband both split outputs will remain at zero Note A third output CVnA3 is displayed online and should be ignored Deadband hit 0 PID Output Figure 9 2 CV Standard Split Output Function CV standard splitter prompts Table 9 28 describes the Standard Splitter prompts Table 9 28 CV Standard Splitter Prompts 5 00 PARM analog Prompt Range Selections Definition Full name IDPT XX XXXX Input Decimal Position Move the decimal point to XXX XXX the position used by the inputs to the
209. e output to be on for 75 seconds and off for 75 seconds when the input source is at 50 Variable impulse time is available by programming a CN constant block s Destination with IT See Programming Constants Section 9 9 5 00 UDC5300 Controller User Manual Using Program Mode to Configure Function Blocks and Features Table 9 11 DAT Analog Output Prompts Prompt Applies Range Selections Definition Full name To MON DAT OFF Min On Time and Min Off Time Specify the minimum time the output should be ON and OFF Min On Time NUMBER even if the output source calls for less time MOFF Take into account the requirements of the device being controlled when configuring these times Min Off Time Some motors can be damaged if cycled on and off too quickly Failsafe Value Sal NUMBER output will be held when failsafe is active This value is also the initial output of the loop on cold start If the value is set to OFF the output will go to 0 Value entered is in terms of the AO s input source not in terms of the output as defined by FSV CAT OFF Failsafe Value Specify the value at which the OVLL and OVHL output used to implement DAT control OUT DAT DOO Discrete Output Channel Specify the discrete Discrete Output DO1 Channel DO Select DOO for None DO3 The input and action of the selected DO function block will be unprogrammable under the PRG DO DO4 menu item 9 32 UC5300 Controller
210. ea press ENTER ATTENTION Remove this page for security 5 00 UDC5300 Controller User Manual B 1 Security Bypass Procedure B 2 UDC5300 Controller User Manual 5 00 C calculation See carbon potential CV X kk On display 13 6 A ABRT Pretune COMP prompt 13 4 ABRT Pretune IDENT and CALC prompt 13 4 ACST DI parameter 9 35 ACST DO parameter 9 37 ACTN AL parameter 9 67 ACTN CV PP parameter 9 40 ACTN CV SSEL parameter 9 42 ACTN CV TOTL parameter 9 52 address 18 2 Advanced Atmosphere Control Corp 12 3 12 4 advanced PID control selection 9 14 advanced splitter CV 9 61 9 63 ADVNCE setpoint profiler STATUS prompt 11 11 AI block description 5 7 parameters 9 3 9 1 1 use with carbon potential CV 12 8 AIADJ DATA ENT prompt 15 12 AL block description 5 6 parameters 9 67 9 68 ALARM DATA ENT prompt 15 11 ALARM DS STATS prompt 17 11 17 12 alarm block See AL block alarm setpoints changing online 15 12 programming 9 68 viewing 15 8 15 9 alarm summary 15 8 15 9 alarms adding to factory configuration 7 6 programming 9 67 9 68 ALARMS FEATURES prompt 5 36 9 76 ALGR AI parameter 9 3 ALRM SUM SUMMARY prompt 15 7 A M SEL SECURITY prompt 9 79 A MS LP parameter 9 25 analog input block See AI block analog inputs accuracy of linear types 2 7 accuracy of non linear types 2 8 and factory configuration 7 4 calibration 19 2 19 4 p
211. ease letbane 9 16 Table 9 AOU PUL YD x4scste ceca das re eee enes roede een a a eaaoeatica said 9 27 Table 9 10 CAT and VAT Analog Output Prompts cc ccessssssssseececeeeeeeeeeeecaaaaeessesseeeeeeceeeeeeeeeeaaaas 9 29 Table 9 11 DAT Analog Output Prompts 0 0 0 0 cccccccccccccsssssssesesseeeeeceeeeeeeeeeesaaaaseeessssseeeeeeeeseeeeenaaaas 9 31 Table 9 12 PPRA loz Out Promp ien aa sea eee rcs a aaa 9 33 Table 9 03 Discrete Input Prom BIS aa oe stier lee seedede lebe hede a ane orderne 9 35 Table 9 14 Selections for ONL and OFFL Parameters W u u u sssssssesessesseseeeeeense se esnnennrnseseeeesnssneenes 9 36 Table 9 15 Discrete Output Prompts corsa eee eg a E Eia 9 37 TapE gGCV EYE BESES SEERE BEDE SES SD SEE ES mae ene Tene Onan Sonn her men ym RE SEEDEDE RER Minn met ny Tene er 9 38 Table 9 07 CN Peak Piekna Prompt sessione aicaseaticasneieet 9 39 Pable 9 13 C V Sienali elect Prompts xs asgsc ts ie ah eke ae es del ad ited 9 4 Table ARIIN CV Ma Promp iS eaa Parca aaa a a an 9 43 Fable VO CV EOC PrOMmMp S neni aa es a ala aah eat 9 46 Table 9 21 CV Condition Time and Condition Type Prompts ccccccccccecceeeseeesseeeeeeceeeeeeeeeeeeeaas 9 48 Table 9 22 CV Logical Operator Definitions asirese a a e E eden 9 50 Table 9 23 CV Totalizer PrOD Seas E 9 51 Table 9 24 CV Interval Timer PrOD eani a ce gohan tae een de ba oase 9 54 Table 9 25 CV Periodic Timer Prompts sitscaesintescasscanchersatisasnateciersitelicasantisa
212. ecome familiar with these operations 16 If the optional data storage feature will be used to store 17 process data and operator actions Select the data to be stored and specify under what circumstances it will be saved 17 If the serial communications option will be used 18 Configure communication parameters 18 Display part number and version of firmware Note these for 19 future reference If you call for technical assistance you will need this information The manual also contains e information about diagnostics status messages and system error messages Section 21 e instructions for setting an output board s switches to change from CAT to VAT operation or vice versa Section 20 e instructions for resetting the unit clearing the memory calibrating the analog inputs and outputs Section 19 e parts list Section 22 UDC5300 Controller User Manual 5 00 Specifications and Model Number 2 Specifications and Model Number 2 1 Overview This section provides hardware specifications and the model selection guide What s in this section The following topics are covered in this section Topic Page 2 2 Specifications 2 2 2 3 Model Selection Guide 2 9 5 00 UDC5300 Controller User Manual 2 1 Specifications and Model Number 2 2 Specifications Table 2 1 shows the UDC5300 specifications Table 2 1 Specifications Physical Drawn aluminum case with high impact resista
213. eeeeeeaaas 12 11 Table 12 11 CN3 Configuration for Dynamic Setpoint High Limit eseeeeeeeeeeeeeceeeeeeeeeans 12 11 Table 12 12 CV3 Configuration for Splitting Output cecessssseeeeceeeeeceeeeesseeesseeeeceeeeeeeeaaaas 12 12 Table 12 13 AQO3 Configuration for DAT Output sotir a 12 12 Table 12 14 AO4 Configuration for DAT Output 0 cc ccessssssssseeeeeceeceeeeeeeecaaaeeeeeeeeeeeeeeeeeeeeeeaaas 12 13 Table 12 15 CV4 Configuration to Enable Display of DewpoiInl cc ccccccessseseeseeeceeeeeeeeeeenaas 12 13 Table 12 16 Displays Used by Carbon Potential Example ccccccccccccccccccecceeeeeeseeeeeeeeeeeeeeeeenaas 12 14 ADI A tk Aes OE ie Ue ates ttc alas hanes TERESE NER ESS JERES TRES SES SER STEDE REFERERE tact NES ERE ERE VEN SER ER SEERE ER RSSSYESR 13 2 f KE SR 2 Pretium STOP Par Orn p tig xis een N RD SES S A a E REDE ETERN SSD ESEE SE NER 13 2 Table 53 Prene IDENT and ALC Prompts i ea E O A 13 4 Fable 3 Pretune COMP Prone s wigs Sites tists ie ees Sane nate Sao heals aster shade idee dace 13 4 Table 155 Prene ADORE NESS CS stiches ae xa es E bats ohweinaatbndlaveannecdeeeedede 13 5 Table 1st Primary TS Olay Senca SENDER Sal oc easyer atran SEERE TS SEES eel ied miter RSS REESE RESERVERE ERE USED ER SE ERE 14 4 Table 15 1 How To Togsle and or Tune A LOOP i en hane et de NA 15 3 Table IS Loop Tunne Ra ain ES sass ics a i a En Seale alanis kata Rattan aad Eben NL SES 15 4 ADS ES STRE SS 1 One IAL 20 0 1 2 3 S
214. ees 8 6 Figure 8 7 Control of Wastewater pH Using a Time Proportioning DAT Control Signal 8 7 Figure 8 8 Function Block Diagram of Figure 8 70 00 ccccccccccssssssssessssesceceeeeeeeeeeeaaaaesessseseeeeeeeeeeeeaaaas 8 8 Figure 8 9 Temperature Control of Water Using Split Output or Duplex Control 8 9 Figure 8 10 Function Block Diagram of Figure 8 910 ccccccccssssssssseeeeeeeeeeeeeeeseeaeessssseseeeeeeeeeeeeeeeneaaas 8 10 Figure 8 11 Temperature Control of an Oil Heated Chemical Reaction Chambet ceeeeeeeees 8 12 Figure 8 12 Function Block Diagram of the Cascade Control Strategy 0 0 cccssssssesssseeeeeeeeeeeeeaes 8 13 Figure 9 1 Math CV Feedback Programming cccccccccccccsssssssssesesseeeecceceeeeeeeeeeauaaaeseseeeeeeeeeeeeeeenaqaas 9 45 Figure 9 2 CV Standard Split Output Function sisii tobenet tree adda ee ecco 9 59 Figure 9 3 CV Advanced Splitter Default Outputs 1 1 1 W W W u sssssseeeeeeseeeeesnnereeeen enn eee nennnenee een e sneen nensrsseee 9 61 Fiotire 9 4 Compare Siemal FloW oa aA ha RE RER Bal asc Re aed kan stots hehe sons Ale 9 65 Figure 9 5 Compare s Greater Than Result With Hysteresis cccccccccccccceeccccccececeeeeeeceeeeeeeeeeeeeeess 9 66 Fire TOT Factory ComiieuratiOm CEEL 0 ai eribr ss ie dere sende becasue noe hk done deal 10 2 Figure 10 2 Wiring for Factory Configuration 11 Shown in Figure 10 1 cecceeecceeeeeeeeeeeeees 10 6 Fure FI Sample Setpoint Prole sec
215. eform programming starting from scratch 6 First time users only Familiarize yourself with the modes 6 menus and use of the keypad to select and change values 7 If using a factory configuration Review the detailed 7 diagram for your strategy and modify any parameter values necessary freeform programming Review the theory of creating a 8 If you are a first time user and have decided to do 8 function block diagram and programming the strategy 9 Do freeform programming and take care of other Program 9 mode functions such as setting the clock and programming security special carbon potential programming instructions then configure the controller as required 11 If position proportional output will be used Follow the 10 special PP programming instructions then calibrate the controller and positioner combination to take advantage of the full travel of the actuator 10 If the carbon potential option will be used Refer to the 12 12 If the optional Setpoint Profiler will be used Configure the 11 inputs to the profiler and setup one or more profiles 5 00 UDC5300 Controller User Manual 1 11 Introduction Sequence Task Section 13 Pretune the loop s and perform other final commissioning 13 tasks 14 First time users only Become familiar with operator 14 and 15 displays and Online mode functions 15 If the optional data storage feature will be used to store 16 calibration and configuration data B
216. elected System SY Outputs discrete status of alarms data storage and 1 5 2 4 Brief Descriptions of Block Types Introduction This subsection is intended to provide enough information about each function block type to give you an idea of the raw material available to build control strategies Inputs and outputs are emphasized here With the exception of the system block every function block uses configurable internal parameters to determine how it processes data All configurable parameters including these internal parameters are described in detail in Section 9 5 00 UDC5300 Controller User Manual 5 5 Planning 5 2 4 1 Alarm Block Use Use alarm type AL function blocks to monitor process values An AL block can be programmed as a traditional high or low alarm as a deviation high low or both or as a high or low rate alarm Hysteresis and delay time are configurable The initial alarm setpoint is programmed during setup However the operator can change the setpoint while the controller is online Input The input to an AL block is usually the output of the analog input block interfacing with the field device providing the process variable value to the controller However an AL can be programmed to monitor another analog value such as the reference junction temperature available from system block parameter SY1 RT Output When an alarm is active an indicator lights on the display For additional alarm ann
217. ended vertical spacing is 32 mm 1 250 in between cutouts This will allow 25 4 mm 1 00 between bezels of adjacent units 5 00 UDC5300 Controller User Manual 3 3 Unpacking Preparation and Mounting 203 2 8 00 Min i 52 12 7 06 500 Panel Rear of box 96 i Mounting Bar slots 92 3 78 top amp bottom 3 62 dd Panel Cutout 40 6 1 60 191 8 7 55 216 9 8 54 NOTE Dims in mm in NEMA 12 with data storage option requires Panel Gasket part no 30756683 001 between unit and panel Notched end of bar towards thin panel Mounting Bar part no 046943 Panhead screw part no 046977 Thin panel mounting install bottom bar the same as the top bar Notched end of bar Bezel away from thick panel Panhead screw part no 046977 Thick panel mounting install bottom bar the same as the top bar Over tigtteningthe screws may prevent bezel from latching properly Figure 3 1 Mounting 3 4 UDC5300 Controller User Manual 5 00 4 1 Wiring 4 Wiring Overview This section contains instructions for installing ac power wiring and connecting signal wiring to the controller This controller is a complex electronic device measuring low level electrical signals Proper site preparation and installation practices are important in achieving a trouble free system Experience indicates that many problems are the result of improper install
218. er interval See interval timer CV timer periodic See periodic timer CV TIMR CV PTIMER parameter 9 56 TMPU AI custom parameter 9 10 TMPU AI standard parameter 9 4 TO CHNL COPY BLK prompt 9 73 totalizer CV 9 51 9 53 TPIN CV CARBON parameter 12 4 TPLL CV CARBON parameter 12 5 TPUN CV CARBON parameter 12 5 TREND DS STATS prompt 17 11 17 12 TSET Pretune STOP prompt 13 2 TUNE indicator 13 3 TUNE LP Online menu item 15 3 tuning parameters and factory configuration 7 5 changing values 15 3 15 6 dynamic 9 71 limiting access 9 79 pretuning 13 2 programming 9 17 9 20 TUNIT PROFILE prompt 11 5 TUNT CV TOTL parameter 9 52 TYPE AI standard parameter 9 4 TYPE AO parameter 9 27 TYPE CV parameter 9 38 TYPE LP parameter 9 14 U UNITADDR SER COMM prompt 18 2 unpacking 3 1 3 2 update rate See scan frequency y VALADJ FEATURES prompt 9 76 15 11 VAT output DIP switch settings 20 1 20 5 powering slidewire feedback 10 5 programming 9 29 9 30 version viewing 15 7 viewing parameter values 6 12 6 14 voltage output See VAT output W W2 and W3 jumpers 18 4 warm start 19 8 WILD LP parameter 9 22 wiring 4 1 4 16 wiring diagrams for factory configurations 7 8 7 60 WS TIME Maintenance menu item 19 8 X Xn AI custom parameter 9 11 5 00 UDC5300 Controller User Manual Index 7 Index Y Yn AI custom parameter 9 11 Z
219. erating parameters 4 digits Also provides guidance during controller configuration Control loops Number 1 or 2 Type PID On Off TC and EMF types Resolution 15 bits 14 bits plus sign Scan Rate 125 msec 1 analog input only 250 msec 500 msec 1 sec 1 or 3 analog inputs Normal Mode Rejection 60 dB 1000 1 Common Mode Rejection 120 dB 1 000 000 1 100 ohm source Normal Mode Voltage Limit RMS equal to high span limit mains line frequency Common Mode Voltage Limit 400 volts peak Isolation Fully isolated 400 Vdc peak Input Impedance gt 20 megohms Accuracy See Table 2 2 and Table 2 3 MeasurementResolution Accuracy See Table 2 2 and Table 2 3 Temperature Effects See Table 2 2 and Table 2 3 Ranges Assigned per input based on range table TC EMF Source Resistance Error 0 3 microvolts per 100 ohms Reference Junction Error TC only 0 3 C 0 5 F Open Input Check Bleeder type upscale downscale off RTD Inputs 2 Excitation Current 0 15 mA Switching Common B lead Maximum Lead Resistance 5 ohms Accuracy See Table 2 3 Resolution See Table 2 3 Temperature Effects See Table 2 3 2 4 UDC5300 Controller User Manual 5 00 Specifications and Model Number Table 2 1 Specifications continued Analog Output Algorithms Number 1 current standard others selectable Type CAT VAT DAT PP DIAT ON OFF CAT Current Selectable from 0 to 20 mA 2 maxi
220. eration Every control loop except ON OFF type must have feedback to operate The loop LP block has an input pointer for this purpose The analog output AO block and calculated value CV block types each have an output value that can be used by this loop feedback input as the source of a back calculation value This verifies that the output generated by the PID algorithm successfully reached the downstream block 1 10 UDC5300 Controller User Manual 5 00 Introduction 1 5 Overview of Installation Configuration and Startup Tasks Setup tasks described in this manual This manual contains instructions for all installation and operation tasks Table 1 1 provides an overview of the installation tasks as well as providing references to the relevant sections of the manual Note that no one needs to read the entire manual If this is the first time you have used a UDC5300 read the first six sections Based on what you learn in Section 5 pick out the subsequent sections that apply to your configuration approach and options used Table 1 1 Overview of Controller Installation Tasks Sequence Task Section 1 Consider the environmental and electrical specs when 2 selecting a site to install the controller 2 Unpack inspect and mount the unit 3 3 Install power and signal wiring 4 4 Specify the mains frequency at your site 19 5 Plan whether to load and use a factory configuration or do 5 fre
221. erface between the control loop and the actuator in the field For this purpose one AO block is associated with each hardware analog output Depending on the model purchased the unit can support one or two hardware outputs AOI is associated with hardware output 1 AO2 is for hardware output 2 e If your strategy uses Duration Adjusting Type DAT or Position Proportional PP control output then the AO block serves as an intermediary between the control loop and the discrete output blocks serving the relays that are wired to the controlled device DAT uses one relay PP uses two Although AO2 can be associated with an actual hardware output for CAT or VAT control alternatively it can be used as an intermediary for DAT or PP control AO3 and AO4 are also available for use in DAT and PP control Remember though that AO3 and AO4 are software objects only and can never be associated with a physical output terminal Note that ON OFF control loops do not use an AO as intermediary This is the one case where a discrete output can be programmed to read the output of a control loop directly The loop simply turns a relay on and off through the discrete output block Because of this flexibility in the use of AO blocks the first step during AO programming is specifying the correct type of output for your strategy The prompts for the appropriate AO internal parameters will then be displayed Most strategies use the output of a loop as the input to the
222. erve as the reset Value discrete or specify a value directly When the RST goes to 1 an UP action totalizer will reset to zero ora DOWN action totalizer will reset to the preset value ZCUT OFF Zero Cutoff Specify the least value to be accumulated in the totalizer Input values below this value will be input as zero TUNT SEC Time Unit Configure this to match the time units of the flow rate being totaled For example if the flow rate is in gallons per minute select MIN 9 52 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 23 CV Totalizer Prompts Prompt Range Selections Definition Full name the On Demand input for the DEMD action Activates ENABLE totalizer when ENAB 1 ENAB OFF Enable Specify the parameter whose input will be Output Low Limit and Output High Limit Specify Output Low Limit NUMBER the output range i f Output High Limit value will flash to alert the operator of an unusua OVHL If the output is outside the range the displayed condition The output will not be clamped 5 00 UDC5300 Controller User Manual 9 53 Using Program Mode to Configure Function Blocks and Features 9 7 6 CV Interval Timer ITIMER Introduction This timer counts down from the preset value in minutes range of 0 1 to 9999 9 minutes This time remaining is CVn OV The timer has a single discrete output CVn OS which is ON 1 while
223. es The analog output block used must have its output type specified as PP and it output positioning algorithm specified as PP If the positioning device does not provide feedback then use the loop type DIAT Direction Impulse Adjusting Type When configuring the analog output block specify the output type as PP but then select the output positioning algorithm as DIAT If the positioning device does provide feedback under normal operation but you want to use direction impulse adjustment if the feedback fails program the loop type as DIAT the output type as PP and the position algorithm as AUTO Many of the prompted entry fields for control loops are optional As a general rule the minimum entry information for control loops includes the Process Variable PV with range limits setpoint value some combination of gain reset and rate and a source for the feedback In most cases the feedback source will be the back calculation output BC value of the analog output AO function block UDC5300 Controller User Manual 9 13 Using Program Mode to Configure Function Blocks and Features Table 9 5 Loop Characteristics Characteristic What to be aware of Split output When the LP type is SPLIT a calculated value CV block must be programming used to send the split loop s output to two standard splitter or three requirements advanded splitter analog output AO blocks Pro
224. es contain the data entered through the Online mode Profile Edit function but do not contain information entered through the Program mode Parameters configured during Program mode are stored when the entire configuration is stored as described in Section 16 When storing the profile you will have the opportunity to assign a name by selecting one of profile type choices and appending a number from to 99 ATTENTION Before inserting or removing a card be sure to discharge any static buildup on your body or clothing Procedure for storing a profile The procedure for storing a profile is provided in Table 11 3 This procedure assumes that you know how to lift up the front of the controller and insert a PCMCIA card If you need instructions for those tasks see Section 16 Table 11 3 Procedure for Storing a Profile To store a completed profile the profiler must be in the ENDed or Ready state Insert a PCMCIA card into the controller and close the bezel 2 Select PROFILE from the Online mode Menu and advance to the PRF STOR menu selection Press ENTER to start the procedure The display will change to STORE PROFILO1 3 To select a different name and number press the DECREMENT VW key The display will change to STORE FILE 01 4 Press the W key to scroll through the name choices When the name string you want is displayed press ENTER The controller is now ready for you to change the number 01
225. ete list UDC5300 Controller User Manual 5 15 Planning Diagram Loop LO O00000 PV SP2 setpt 2 value WILD ratio only MOFF manual off on off type only FB feedback FFIN feedforward input OTRK output tracking value RMAN remote manual status CHGA change action DTUN tuning parameter set selection DIKY a m and setpt sel from keys or discretes SPSE OV output value PV retransmitted DV deviation WS working setpoint S1 setpoint 1 value S2 setpoint 2 value BC back calculation value AM auto manual status SS setpt1 setpt2 status OS output staus on off type only setpt sel when DIKY 1 A MS a m sel when DIKY 1 OOO UDC5300 Controller User Manual 5 00 Planning 5 2 4 9 Setpoint Profiler Block Use Input Output 5 00 An optional feature is the setpoint profiler When this feature is included in the model a SP function block is programmable The SP block does not process data Instead it is used to generate a setpoint for control consisting of up to sixteen ramp or soak segments These segments are programmed based on setpoint value and time Two event outputs can be used to initiate discrete actions during particular segments Internal parameters can be used to program the profile execution to be held if an analog value usually the PV deviates too muc
226. exit the function Remove the card 5 During the loading operation the display will read FILE LOADING When the UDC5300 Controller User Manual 11 9 Configuring and Using Setpoint Profiler 11 6 Using a Setpoint Profile Introduction Once a profile has been defined as described 11 4 it can be used to provide the value of setpoint 2 to either loop Online operation is controlled through two menus one is accessed by pressing the SETPOINT PRGM key the other appears in the Online menu SP PRFLR only when a profile is active Both menus are explained here Using the SETPOINT PRGM key To cycle through the item in Table 11 5 press the SETPOINT PRGM key repeatedly Table 11 5 SETPOINT PRGM Key Menu Prompt Definition Full name Status can be RDY Ready Available to start running SPP indicator OFF ACT Active Profile is running SPP indicator ON HLD Held SPP indicator FLASHING STATUS Shows profile s current segment number and status END End Finished must reset to run again SPP indicator OFF SET PT Indicates the current output value of the profiler Setpoint SEG n Current segment number and time remaining in Semeni segment E TIME Indicates the elapsed time since the profiler was ians Time started including any holds EVENTS Shows the ON or OFF status of event outputs 1 and 2 FILENAME Shows the name of the currently running profile 11 10 UDC5300 Con
227. f the two event discrete outputs E1 and E is specified By selecting one of these outputs as the input source for another block you can program the controller to take an action such as closing a relay during any segment for which you have programmed E1 to be ON The setpoint calculated by the Setpoint Profiler s function block SP1 is available as the output value SP1 OV This one profile can be used by both loops of a two loop controller Select SP1 OV as the source of SP2 Setpoint 2 for each loop Deviation hold A single set of deviation hold entry values are provided for the entire profile The deviation hold feature may be disabled or activated on any segment to allow set point guarantees on soak segments only when desired When active the deviation hold feature allows separate enable and disable entries for each loop of the controller The profiler supports discrete inputs which reset run and hold the profile s operation 11 2 UDC5300 Controller User Manual 5 00 Configuring and Using Setpoint Profiler 11 3 Defining the Profiler Inputs and Range Introduction To program the Setpoint Profiler function block SP1 select PRG SPP from the Program mode menu PRG SPP will appear only if the Profiler is in the READY or ENDed state Setpoint Profiler prompts Error Reference source not found describes the Program Setpoint Profiler prompts Input Decimal Position Output Decimal
228. field signal and the rest of the controller functions For example the analog input AI block UDC5300 Controller User Manual 5 00 Introduction type converts the incoming voltage signal to a value usable by other blocks such as the loop LP block executing the control algorithm Analog output AO blocks can provide your choice of current adjusting type CAT voltage adjusting type VAT duration adjusting type DAT and position proportioning PP output In addition direction impulse adjusting type DIAT output can be achieved with a special DIAT PID control algorithm and the PP output type configured to use the DIAT positioning algorithm Function block complement In addition to the function blocks that interface with the analog inputs and outputs AI and AO and discrete inputs and outputs DI and DO four other block types perform a wide variety of functions Two LP loop blocks execute your choice of standard PID advanced PID PID ratio PID with DIAT output PID cascade or ON OFF control Two sets of tuning parameters can be programmed for each PID strategy switching between the sets is fast and easy The switchover can be triggered from an external device Sixteen CV calculated value blocks can each perform any of twelve functions such as peak picking interval timing math or logical operations or output splitting for greater flexibility when configuring your strategy For example inserting a standard split
229. for the time period specified using this prompt Enter a starting value or OFF at the time of configuration The value may be altered online for final loop tuning 15 4 UDC5300 Controller User Manual 5 00 Approach High Setpoint 1 and SPT2 Setpoint 2 Increasing Slew Limit and DSLW Decreasing Slew Limit 5 00 Using Online Menu Functions Table 15 2 Loop Tuning Parameters NUMBER range is 100 to 100 NUMBER range is 0 1 to 100 NUMBER range is 0 1 to 100 NUMBER NUMBER NUMBER range is 0 to 100 of PV span UDC5300 Controller User Manual Manual Reset This feature functions only when OFF is entered for RST1 and RST2 Enter a value equal to the desired loop output when the process variable is at setpoint This allows correction of output to account for load changes to bring the process variable up to setpoint The controller output is the computed output value plus the value of MRST Approach High This function affects the process variable approach to setpoint when the process variable value is less than the setpoint value The value entered is the percent of span deviation from setpoint at which a recalculation of the loop integral value will occur This function is useful for batch startup from a cold condition to control excessive overshoot when setpoint is reached Approach Low Value entered affects the process variable approach to setpoint when the process var
230. fore these secondary routines are enabled Importance of feedback Configuration errors may also cause function blocks to fail to operate on startup One common error is to omit the feedback source for a PID algorithm With the exception of ON OFF control the loop must have feedback to operate The feedback is used to verify that the output generated by the PID algorithm successfully reached the controller output block The AO and CV blocks provide a BC back calculation output value for this purpose Sometimes however during configuration the need for feedback is ignored by the programmer Most signal flow is forward through the controller as the incoming field signal is processed and its value used and manipulated by various blocks until a value is processed into a field signal to the controlled device However the loop feedback connection is sometimes forgotten because it is in the reverse direction from AOn BC back calculation output back upstream to LPn FB feedback input Although the loop must have feedback to operate some function blocks do not propagate a back calculation value providing the output value that is needed for PID control loop operation If your configuration uses one of these blocks between a PID loop and an analog output use the control loop s own output value LPn OV as the feedback source for the loop to complete the signal flow connection Take advantage of the summary displays
231. ge ESD The damage incurred may not cause the device to fail completely but may cause early failure Therefore it is imperative that assemblies containing static sensitive devices be carried in conductive plastic bags When adjusting or performing any work on such assemblies grounded work stations and wrist straps must be used If soldering irons are used they must also be grounded A grounded work station is any conductive or metallic surface connected to an earth ground such as a water pipe with a 1 2 to 1 megohm resistor in series with the ground connection The purpose of the resistor is to current limit an electrostatic discharge and to prevent any shock hazard to the operator The steps indicated above must be followed to prevent damage and or degradation which may be induced by ESD to static sensitive devices Wiring for immunity compliance In applications where the power input or output wiring is subject to high level electromagnetic disturbances shielding techniques will be required Grounded metal conduit with conductive conduit fittings is recommended In all applications separation of low level wiring and high level wiring is recommended To avoid electrical interference with signals do not run low level signal leads close to or parallel with line voltage leads or other power leads Twisted signal pairs and shielded cable will improve noise immunity if wire routing is suspect Conform to code Instrument wiring is to
232. ge Selections Definition Full name To Ratio Bias Variable Bias is available by programming a CN constant block s Destination with RB See BIAS RATIO OFF Ratio Bias Enter the value of ratio offset Programming Constants Section 9 9 WILD RATIO OFF Ratio Wild Variable Select the function block whose output value will provide the wild variable Ratio Wild NUMBER value to the loop The wild variable is the process Variable PARM analog value that fluctuates with the requirements of the process The controlled variable will be proportioned to the value of the wild variable based on the ratio setpoint A number may be entered to serve in place of the wild variable This may be useful during troubleshooting To use an output value from a CN function block select PARM PVTR STD NONE Process Variable Tracking When PV is ADV selected process variable tracking is enabled Process ON_OFF PV This means that Setpoint 1 of the control loop will Variab le RATIO track the process variable when the loop is in Tracking DIAT Manual mode A transfer to Automatic mode will SPLIT maintain the tracked setpoint value as the active setpoint of the loop unless the loop was operating from Setpoint 2 prior to the transfer to Manual SPID ADV NO Soft PID Action When YES is selected soft PID RATIO action is enabled This causes the control Soft PID CAS P YES algorithm to not calculate proportional output Action CAS S correspo
233. gram the control loop to receive a feedback from the back calculation output of the splitter calculated value In other words loop Feedback CVn BC where CV nis a splitter type calculated value and BC is its output Program the splitter calculated value to accept the back calculation values BC of each analog output function block AO as its feedback source In other words CVn FB AOn BC Loop programming procedure To program Control Loops select PRG LP in the Main Program Menu Select LP1 or LP2 to program then select a loop type listed in Table 9 6 Table 9 6 Loop Types STD Standard Loop ADV Advanced PID Loop ON OFF On off Loop RATIO Ratio Loop CAS_P Cascade Primary CAS_S Cascade Secondary DIAT Direction Impulse Loop SPLIT Split Loop Table 9 7 lists the prompts for the various control loop types See Table 9 8 for descriptions of these prompts Enter all desired choices then repeat the procedure if desired for the other Loop LP 1 or LP 2 9 14 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 7 Control Loop Prompts lI STD I ADV II ON OFF II RATIO I CAS P I CAS S I DIAT I SPLIT do wer w wer et et Wo mer wW pemr pmr pom I oort oort oor oor W oorr W oort W oort oorr I pv Ev i ev I ev I rv I HO eve Eevee dL pva W pva W pva W pva WO pva W pva WO pva Pv I Wo cma E cma W cma W cma W cm
234. h from a specified value Because the setpoint profiler does not process data it has no traditional inputs It does not need to read a value from another block to perform its function However some internal parameters can point to other function blocks For example the source of the value to which the setpoint profiler s output is compared for deviation calculation during profile execution can be an analog value from another block The profiler s operation can be set to hold or run based on the value of a discrete output from another block The output of the profiler is the setpoint always the loop s SP2 when the profile is being executed In addition this value can be read from the analog SP OV parameter The deviation hold value and segment number are also available as analog output values A number of discrete status values are also available to be read by other blocks See Table 5 3 for a complete list UDC5300 Controller User Manual 5 17 Planning Diagram Setpoint Profiler SP e DPL output value DPL2 PV p values to be compared loop 1 to profiler output for deviation loops 1 and 2 pause RRIN C reset run i input segment number HOLD SH hold profile C ee on hold status SE end status SA active status SI active or held status SR ready status E1 event 1 output E2 event 2 output de e a a 5 18 UDC5300 Controller User Manual 5 00
235. h with ON OFF Relay Description Two independent loops each use a linear input signal served by an analog input AI block for the PV Each uses a relay served by a discrete output DO function block for ON OFF control Basic diagram Analog Input 1 PID PV Loop1 0 100 Analog Input 2 PID PV Loop2 0 100 Wiring diagram Alt SER KKR SAM a Orel SIIS ISI Ar L2 N QC EEA 1S LOAD 0 JEE ami I o OQ OO CO Load Supply Ql OTOL LS LOAD SRI S44 Load Supply x Al2 7 58 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Programming diagram Al1 TYPE LP1 PV Al1 OV LP1 TYPE DO1 INP LP1 OS C DO LINEAR ON OFF Al2 TYPE LP2 PV Al2 OV LP2 TYPE DO2 INP LP2 OS C DO LINEAR ON OFF 5 00 UDC5300 Controller User Manual 7 59 Using a Factory Configuration 7 60 UDC5300 Controller User Manual 5 00 8 1 Learning to Create Custom Programs 8 Learning to Create Custom Programs Overview Introduction This section is intended to show first time users of the UDC5300 controller how to approach the task of creating a custom program If you plan to use a factory configuration this section provides more details than you need to know It provides sample applicat
236. hardware output for CAT or VAT control alternatively it can be used as an intermediary for DAT or PP control AO3 and AO4 are also available for use in DAT and PP control Remember though that AO3 and AO4 are software objects only and can never be associated with physical output terminals Note that ON OFF control loops do not use an AO as intermediary This is the one case where a discrete output can be programmed to read the output of a control loop directly The loop simply turns a relay on and off through the discrete output block To complete an ON OFF loop configuration assign the ON OFF loop s output LPn OS to a Discrete Output Relay see Section 9 6 Because of this flexibility in the use of AO blocks the first step during AO programming is specifying the correct type of output for your strategy The prompts for the appropriate AO internal parameters will then be displayed To program the Analog Output function blocks select PRG AO on the Main Program Menu Select an AO to program Specifying the type of output 5 00 The first step in programming an AO function block is to specify the output type The available types are listed in Table 9 9 Table 9 9 Output Type CAT Current Adjusting Type VAT Voltage Adjusting Type DAT Duration Adjusting Type PP Position Proportional UDC5300 Controller User Manual 9 27 Using Program Mode to Configure Function Blocks and Features Analog output pro
237. hat determines the type of algorithm used by the loop Values for internal parameters are always either numbers or a string of characters selected from a list 5 2 2 How Function Blocks Work Together Data flow depends on programming Values flow between the function blocks based on the programming of the function blocks With the exception of the system function block and the setpoint profiler every function block type has at least one input parameter and at least one output parameter Input parameters are used to specify where a function block reads its incoming data Although an input can be configured to be a number usually the source of the input is another block s output For example the input process variable of a loop block would be the output value from an analog input block This same output value could also be the input for an alarm block When you have to specify another block s parameter as the source of data for the block being programmed you are presented with a list from which to make your selection Function blocks interface with field signals 5 2 Each input and output supported by the controller s hardware is associated with its own instance of the appropriate function block type The input or output s function block interfaces between the field signal and the rest of the function blocks in the controller Each hardware discrete input is served by a DI block and each output relay by a DO block If another b
238. he controller to process the field signal providing the input to the Al function block STD STANDARD Use STD if one of the standard algorithms for an input type listed in Table 9 3 will be used The prompts available when STD is selected are shown in Table 9 2 CUSTOM Select CUSTOM if conversion of the input from a thermocouple EMF or RTD to engineering units must be done using a custom curve Use the prompts in Table 9 4 when CUSTOM is selected to specify the custom curve by defining up to 20 points Algorithm CUSTOM 5 00 UDC5300 Controller User Manual 9 3 Using Program Mode to Configure Function Blocks and Features Standard analog input algorithm prompts Table 9 2 describes all the prompts associated with the standard analog input algorithm These prompts are displayed if STD is selected in response to the ALGR prompt Out Decimal Position Out Units Range Low RGHI Range High Temperature Unit Table 9 2 Standard Al Algorithm Prompts See Table 9 3 for Type Used to specify the standard input type available choices measurement or linear type is selected The default type is LINEAR XX XXXX Out Decimal Position Move the decimal point to the XXX XXX position to be used in the output value provided to other XXXX XX function blocks and the optional data storage database by XXXXX X the Al block XXXXXX NONE Out Engineering Units Unit of measure Fa
239. he operator When STATUS is on display using the A and V keys to access HOLD item see Table 11 4 e Selecting START cancels the manual hold and resumes execution at the point where it was held e To resume at a different segment use the A and V keys 2 By the value of a discrete changing When SP1 HOLD 1 the profile is held A logic low O returns the profile to the active state 3 Based on analog value High deviation If SPDPL1 or SPDPL2 deviation parameter input is greater than SP1 OV setpoint profiler output by more than the DVPHL deviation high limit profile holds see Table 11 2 4 Based on analog value Low deviation If SPDPL1 or SPDPL2 deviation parameter input is less than SP1 OV setpoint profiler output by more than the DVPLL deviation low limit profile holds see Table 11 2 5 Based on controller mode Changing into Program or Maintenance mode will hold execution of the profile Indicator does not flash Profile execution resumes when Online again Resetting a Profile A held or ended profile may be reset to the Ready status by two methods 1 By operator Using the SETPOINT PRGM key and the A and W select STATUS RESET see Table 11 4 2 By the value of a discrete changing When value of discrete SP1 RRIN changes from logic low 0 to logic high 1 the profile resets A logic high 1 to logic low 0 change restarts the profile Advancing the profile I
240. her parameter or NONE the original destination parameter maintains its last live value as determined by the constant s input If you want the destination s last live value to be zero or NONE 1 Change the constant input to zero or NONE 2 Change to online mode for 5 seconds to override the previous live value with zero or NONE 3 Change back to program mode 4 Re program constant s destination to NONE e f you program multiple constants with the same destination only the highest numbered constant s destination takes effect For example if CN1 and CN5 both have DEST AO2 IT then only CN5 s input is used by AO2 IT UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 10 Copying a Block Introduction Use Copy Block to copy the setup of any function block to another function block of the same type For example if you have programmed AI and want AI 2 to have the same settings use Copy Block If desired you can make program changes to AI 2 after the copy is complete Copy block prompts Table 9 33 describes the Copy Block prompts Table 9 33 Copy Block Prompts From Channel Prompt Range Selections Definition Full name BLK TYPE Block Type Select the function block type to be copied Block Type Al Analog Input AL Alarm AO Analog Output CN Constant CV Calculated Value DI Discrete Input DO Discrete Output LP Loop FRM CHNL range depends on Fr
241. hese DO blocks are not configurable for another purpose once they have been designated for use in control Diagram 5 00 Analog Output AO analog f signal out INP OV input output value SLWR BC amp slidewire back calculation gt feedback value UDC5300 Controller User Manual 5 9 Planning 5 2 4 4 Calculated Value Block Use Input Output Use the versatile calculated value CV block type to customize your strategy The CV can be programmed for the following functions peak picking signal selection math or logical operations totalizing interval or periodic timing discrete signal inversion standard or advanced output splitting comparison or computing carbon potential The first step in programming a CV is to specify the type of function Subsequent prompts will be appropriate for this function The inputs used by the CV depend on its type Generally the input can either be specified as a number directly during CV programming or the input can be programmed to read a value from another block s output The CV block type provides a variety of outputs readable by other blocks An analog output value OV or the discrete output status OS is the most commonly used However other special output types are available such as PV which retransmits the input to the peak picking or totalizer type CV blocks See Table 5 3 for a complete listing of CV outputs Special information
242. his process may be likened to manipulating hot and cold faucets regulate water temperature In Figure 8 10 the analog input function block AII is depicted processing the resistance values produced by the RTD The resulting water temperature measurements AI1 OV are then fed to UDC5300 Controller User Manual 8 9 Learning to Create Custom Programs the process variable input PV of the LP1 control loop block Note how LP1 has been defined as a split output control loop using the notation TYPE SPLIT Unique to this control loop is the defined range of its output value LP OV Where the standard control loops mentioned thus far have had outputs ranging exclusively between 0 and 100 the values of the split output control loop vary between 100 and 100 0 is considered the midpoint for this control loop s output range When brought on line a 0 to 100 output value will be generated by LP1 when hot water is needed to maintain the temperature at set point When the addition of cold water is necessary the loop s output will assume a value between 0 and 100 Note that to externalize the control signals generated by LP1 two analog output blocks AOI and AO2 will be used AO1 s 4 mA to 20 mA signal will be tied to the hot water valve actuator while the actuator that adjusts the position of the cold water valve will receive its mA control signal from AO2 To provide AO1 and AO2 with usable input driving signals LP1 s o
243. hrenheit or F Celsius for the output value provided to the optional data storage database C OFF Range Low and Range High Specify the input range NUMBER The values must be within the limits valid for the input type 4 see Table 9 3 except for Pyrometry types which must be exactly as shown in Table 9 3 Be sure to use the correct values for the temperature units used F C K R To enter the full range for the temperature units selected see TMPU select TYPE again and press ENTER without changing the range type Temperature Unit Specifies the input value s unit of measure with thermocouple pyrometer and RTD input types If you change from the default F change the RGLO and RGHI accordingly The range limits will not be recalculated automatically F Fahrenheit C Celsius K Kelvin R Rankine NONE None Use NONE if the input is not a temperature 9 4 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 2 Standard Al Algorithm Prompts Direct Indirect Square Root Direct Indirect Square Root Specifies the category of input source The selection made here affects what other prompts are displayed Direct Input is a direct sensor measurement from a thermocouple pyrometer or RTD Indirect Input comes from a transmitter When INDIRE is selected the voltage input will be linearized Also you will be prompted to
244. iable value is greater than the setpoint value Setpoint 1 and Setpoint 2 Setpoint 1 and Setpoint 2 are independent setpoints Either may be the active setpoint for the loop Setpoints can be changed using some primary displays when the controller is in Online mode Increasing Slew Limit and Decreasing Slew Limit Specify limits for rate at which operator can change the setpoint using the keys on the front panel On OFF Hysteresis The value entered here will be used to define a deadband above and below the setpoint If the PV varies from the setpoint while the output is ON but by less than the value specified here the output will remain ON preventing excessive output oscillation 15 5 Using Online Menu Functions Table 15 2 Loop Tuning Parameters Prompt Range Selections Definition Full name FFGN OFF Feed Forward Gain Specified value is applied as Feed Forward NUMBER gain to the feed forward input value Gal range is 10 00 to 10 00 RATO OFF Ratio Setpoint Enter ratio setpoint RATIO type Ratio Setpoint NUMBER OOS ON OSUP NO Fuzzy Overshoot Suppression When YES is Fuzzy VES selected suppression is enabled limiting the overshoot Overshoot of the setpoint by the process variable after a disturbance in the process such as a load change or Suppression setpoint change Through fuzzy logic the working setpoint of the control loop is dynamically modified by
245. ic diagram Analog Input 1 2 J O hay 0 100 SON Wiring diagram Al1 DO1 AKAROA AOAO AKAROA Programming diagram Al1 TYPE LP1 PV Al1 OV LP1 TYPE DO1 INP LP1 OS C DO1 LINEAR ON OFF 5 00 UDC5300 Controller User Manual 7 33 Using a Factory Configuration 7 4 16 Configuration 16 216 Cascade PID with Current Output Description This strategy provides cascade control in which the setpoint of the secondary loop is read from the output value of the primary loop Each loop uses a linear PV input via an analog input AI block The output is through a CAT current adjusting type analog output AO block Basic diagram Analog Input 2 V Analog Output 1 4 20mA 0 100 7 Analog Input 1 PID re 0 100 Loopit i i Wiring diagram Alt EN ACE OT StS amp or Hol OHS e ER SEE mE 19 S REN ENE S RENSENS ER TEE ESSEN S RENSEN i kai Al2 7 34 UDC5300 Controller User Manual L1 L2 N 5 00 Using a Factory Configuration Programming diagram I2 TYPE LP2 PV Al2 OV LINEAR LP2 TYPE AO1 INP LP2 OV AO1 TYPE 11 TYPE LP1PV LP1 TYPE LP2SPT2 CASS CAT LINEAR Al1 OV CAS P LP1 OV I LP2 FB AO1
246. ify the input range RGHI 2500 D ID DIRECT Because the input is from a thermocouple specify direct input FAIL DOWN Specify that in case of input failure the input value used should be the lower range limit downscale burnout 12 8 UDC5300 Controller User Manual 5 00 Carbon Potential Option Table 12 6 CV1 Configuration to Enable Display of Temperature CV1 Programming Notes TYPE MATH This CV block reads the temperature value from the output OV of OO Al2 and adds zero to it thus making the temperature available as INP1 Al2 OV the CV block s output value INP2 0 The output of any CV block can be displayed on a PVCV type OPER ADD primary display for the loop but not changed by the operator Furnace factor The CARBON type CV block provides a FURN furnace factor parameter The value of FURN will be added to the calculated C before the value is made available as CV2 OV This furnace factor is used to compensate for sensor location or other variables Instead of entering the value directly for the FURN parameter during configuration of CV2 CO a CN constant block is selected as the source of the value This enables the FURN value to be displayed and changed ona PVCN primary display while the controller is online Table 12 7 shows the programming for the CN1 block Table 12 7 CN1 Configuration for FURN Value CN1 Programming Notes
247. ifying the AC Power Frequency 19 8 19 8 Displaying Firmware Version Information 19 8 19 9 Specifying the Power Off Period for Warm Start 19 8 UDC5300 Controller User Manual 19 1 Using Maintenance Mode 19 2 Calibrating Analog Inputs Introduction Periodic calibration of the inputs is recommended to ensure conformity to the specifications Calibration of new controllers is not necessary however field calibration may optimize accuracy if proper eqiupment is used WARNING This procedure should be performed by qualified personnel only Disconnect power to all terminals before connecting or disconnecting calibration leads A potentially lethal voltage is present on the mains terminals and may be present on other terminals More than one switch may be required to disconnect power Select CALIB AI from the Maintenance Menu Select an AI to calibrate Calibrating one analog input results in all analog inputs being calibrated 19 2 UDC5300 Controller User Manual 5 00 Using Maintenance Mode 19 2 1 Calibrating for EMF or Thermocouple Inputs Materials required To calibrate the inputs you will need e ascrewdriver to fit the terminal blocks on the rear of the controller e an adjustable precision 25 mV to 5 V voltage source Procedure The procedure for calibrating inputs used for EMF or thermocouple inputs is provided in Table 19 1 Table 19 1 Analog Input Calibration Procedure for EMP or Thermocoup
248. iguration AO3 TYPE DAT AOS INP AO3 OUT O ER CV9 A1 DO1 4 CV9 FBI AO3 BC i LP1 PV LP1 TYPE CV9 INP CV9 TYPE ae TYPE Alt OV SPLIT LP1 OV SPLT_S AO4 INP AO4 OUT O rn CV9 A2 DO2 4 CV9 FB2 AO4 BC LP1 FB CV9 BC UDC5300 Controller User Manual 7 21 Using a Factory Configuration 7 4 9 Configuration 09 109 Heat Cool with Time Proportioned Relay for Heat and Position Proportioning Relays for Cool Description This PID loop with split output uses one relay to provide a time proportioned output to the heater when the process variable is above setpoint and uses two other relays to provide position proportioning output to the cooler when the PV is below setpoint A control deadband is configurable The split output is achieved with a calculated value CV function block programmed to be a standard splitter A DAT Duration Adjusting Type analog output AO function block interfaces between the loop LP block and the discrete output DO block associated with the time proportioned relay An analog output AO block with both its type and its positioning algorithm set to PP position proportioning interfaces between the loop LP block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO blocks are not associated with analog output terminals The analog feedback signal from
249. ime Proportioned Relays Out Description This strategy provides cascade control in which the setpoint of the secondary loop is read from the output value of the primary loop Each loop uses a linear PV input via an analog input AI block One relay is used to provide a time proportioned output A DAT Duration Adjusting Type analog output AO function block interfaces between the secondary loop LP2 block and the discrete output DO block associated with the time proportioned relay In this application the AO block is not associated with analog output terminals Basic diagram Analog Input 2 PV 0 100 PID O e Analog Input 1 PID Loop 2 ee 1 O 100 Loop1 Time Prop Wiring diagram DO1 GNA NGG CIO OY QO OY V NANA CH CH KH S S S S S Al2 7 44 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Programming diagram Al2 TYPE LP2 PV Al2 OV LINEAR AO3 TYPE DAT LP1 TYPE AOS INP AO3 OUT O men Al1 TYPE LP1PV LP1TYPE LP2SPT2 CAS S LP2OV DO1 LINEAR Al1 OV CAS P LP1 OV LP2 FB LP1 FB LP2 BC POS 5 00 UDC5300 Controller User Manual 7 45 Using a Factory Configuration 7 4 22 Configuration 22 222 Two Independent PID Loops Each with Time Proportioned Relay
250. ined when either the primary controller or the UDC5300 is powered down If the primary controller s output fails ON power will be cut to its output circuit Basic diagram 7 30 Analog Input 1 INC ontrolled ig PV PID 0 100 Loop1 DEC Relay 4 Output Analog Input 2 Position Tracking Proportionin Value j i Analog Input 3 Slidewire F e Feedback 0 100 V Relay 1 Manual Remote Discrete Input 1 Status OOM Relay 3 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Wiring diagram Actuator Voltage DO3 DO1 Primary Controller AKOAKO ORDO 00o QIO CO OOO Programming diagram l1 TYPE LP1 PV DO2 LINEAR Al1 OV LP1 TYPE AO3 INP ADV LP10OV oo 12 TYPE LP2 OTRK LP1 FB LINEAR Al2 OV AO3 BC AO3 TYPE PP AO3 PA PP AO3 INC DO2 I3 TYPE AO3 SLWR AO3 DEC DO4 LINEAR Al3 OV LP1 RMAN DO1 OS DO1 DO1 INP DI1 OS ly DO3 INP DI1 OS CN9 IN AO1 INP 20 CN9 OV AO1 TYPE VAT AO1 INLL 0 AO1 INHL 100 AO1 OVLL 0 AO1 OVHL 5 5 00 UDC5300 Controller Use
251. ing parameters is enabled with DTUN a loop prompt appearing later in the cycle Enter a starting value at initial configuration The value may be altered online for final loop tuning To allow integral only control select OFF Reset in Repeats per Minute Specify how many times proportional action should be repeated per minute second set of tuning parameters This is the integral component of control Reset adjusts the controller s output taking into consideration both the size of the deviation SP PV and the duration of the deviation The amount of corrective action depends on the value of PB2 or GAIN2 Enter a starting value at initial configuration The value may be altered online for final loop tuning To allow proportional only control select OFF When reset is turned off the MRST manual reset value determines the loop output at setpoint Bumpless manual to automatic transfer is cancelled when proportional only control is selected Rate 2 Enter the time period to be used by the derivative component of control which affects the loop s output whenever the deviation between setpoint and process variable is changing The output will be affected more when the deviation is changing faster The output is modified by a value that assumes the rate of change of the process variable will continue for the time period specified using this prompt second set of tuning parameters Enter a starting
252. ing Procedure 1 Place the unit in the panel cutout as shown in Figure 3 1 Optional NEMA 12 from front panel only requires panel gasket part no 046955 between unit and panel 2 Engage the rounded projection on the mounting T bar in the slot on the top of the unit s case Note the end with the notch For thin panels up to 7 92 mm 5 16 in place the notched end toward the panel For thick panels up to 12 7 mm 1 2 in place the notched end away from the panel For thicker panels up to 6 85 mm 1 4 in can be cut off the unnotched end 3 Slide the bar up against the panel and insert the 0 472 in 12 mm long screw at the end of the case as shown Tighten it loosely 4 Install the second T bar and screw in the slot on the bottom of the case in the same way 5 Check the fit and alignment of the unit and tighten the screws on the top and bottom to 3 Ib in 35 N m maximum torque NOTE Three shorter screws supplied are not required for this mounting application Mounting adjacent controllers Horizontal For closest spacing horizontally spacing of 6 35 mm 0 250 in will provide zero clearance between bezels of adjacent units For applications where units will be opened frequently for access to removable cartridge increase this spacing slightly to avoid the possibility of units touching when opening or closing Vertical Space must be allowed for fingertip access to the latch button on the bottom of the bezel Recomm
253. ion Proportioning Relays Out Description Two independent PID loops are configured Loop 1 uses one relay to provide a time proportioned output Loop 2 uses two other relays to provide position proportioning output A DAT Duration Adjusting Type analog output AO function block interfaces between the Loop 1 LP1 block and the discrete output DO block associated with the time proportioned relay An analog output AO block with both its type and its positioning algorithm set to PP position proportioning interfaces between the Loop 2 LP2 block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO blocks are not associated with analog output terminals Loop 2 uses an analog feedback signal from the positioner s slidewire received at AI2 The feedback is powered by a constant 1 V from the terminals associated with AOI and its VAT voltage adjusting type AO function block having an output range from 0 to 5 Because the input to the AO is 20 from a constant CN block a steady 1 V out is achieved 20 of the 5 V range Basic diagram Analog Input 1 v fad BL 0 100 i Time Prop INC Analog Input 3 Relay 3 PID PV i Loop2 0 100 DEC Relay 4 Position Proportioning Analog Input 2 Slidewire Feedback 0 100 Analog Output 1 1 V Power for Slidewire Feedback 7 48 UDC5300 Controller
254. ion software to configure freeform equations such as Input 1 Input 2 SQRT ABS Input 3 Input 4 5 CV math prompts Table 9 19 describes the Math prompts Table 9 19 CV Math Prompts Prompt Range Selections Definition Full name IDPT XX XXKX Input Decimal Position Move the decimal point to XXX XXX the position used by the inputs to the CV block Input Decimal XXXX XX Position XXXXX X XXXXXX ODPT XX XXXX Output Decimal Position Move the decimal point to XXX XXX the position to be used in the output value provided by Output Decimal XXXX XX the CV block Position XXXXX X XXXXXX INP1 OFF Input Source 1 through Input Source 8 Use these prompts to specify the source of the inputs to the CV Input 1 RE function block through PARM analog Attention If connecting to an upstream loop that loop INP8 output LPn OV MUST be INP1 See FB feedback below Input 8 OTEU OFF Output Engineering Units Specify the unit of measure Fahrenheit or Celsius for the output Output F Engineering Units C 5 00 UDC5300 Controller User Manual 9 43 Using Program Mode to Configure Function Blocks and Features Table 9 19 CV Math Prompts Operator Select the math operator to be used by the function block The values provided by the inputs will be the operands The rules follow e f the operator is add subtract multiply or standard deviation the block will do the calculation Input 1 OPER Input 2 OPER
255. ions along with their function block diagrams The first example is a simple control arrangement described in great detail to help you understand function block diagram basics followed by more sophisticated examples Once you understand how to diagram function blocks you will be able to draw a diagram for virtually any control strategy regardless of complexity This section assumes that you are already familiar with the information in Section 5 Planning and Section 6 Modes Menus Prompts and Keypad Basics What s in this section 5 00 The following topics are covered in this section Topic Page 8 2 Programming a Current Driven Heat Treat Element 8 2 8 3 Time Proportioning Relay Driven Pump 8 7 8 4 Split Output or Duplex Control 8 9 8 5 Cascade Control 8 12 UDC5300 Controller User Manual 8 1 Learning to Create Custom Programs 8 2 Programming a Current Driven Heat Treat Element Introduction An example of one of the most common and simple control strategies is in Figure 8 1 below CONTROLLER BG B08 TYPE J THERMOCOUPLE SP 500 OUT 83 5 VALVE FURNACE ZONE ACTUATOR 4 TO 20 mA CAT 0 SUPPLY DE S VALVE BURNER Figure 8 1 Control of Furnace Zone Temperature with 4 20 mA CAT Control Signal 1 Diagram the function blocks To configure this application using the instrument your task is to build up a simple current control loop Note that this control loop must monitor a
256. istor in series with the ground connection The purpose of the resistor is to current limit an electrostatic discharge and to prevent any shock hazard to the operator The steps indicated above must be followed to prevent damage and or degradation which may be induced by ESD to static sensitive devices 5 00 UDC5300 Controller User Manual 18 3 Setting Up for Serial Communications Procedure 18 4 The procedure for terminating the controller is provided in Table 18 2 Table 18 2 Termination Procedure Turn off power to the controller More than one switch may be required to remove power 2 With the power off access the instrument assembly e Open the front of the controller by pressing the button under the bezel to release the latch and then pulling the bezel forward and up The bezel is mounted on bails If you press the bottom of the bezel toward the back of the instrument to compress the gasket slightly the latch will open easily e When the bezel is lifted out of the way a plate is uncovered A latch on either side of the label on this plate holds the instrument assembly in the case e To release these latches insert a screwdriver tip next to the lever on the right side and gently pry the lever to the left while pulling gently on the right side of the bail linkage see Figure 18 1 Repeat on the left latch then using the bail as a handle gently slide the entire card cage assembly forward end of the card cage t
257. it s address Each address on the link must be unique BAUDRATE BYTE ORDER DL LKOUT Download Lockout software BINARY Protocol Select the protocol If the controller is being MODBUS added to a link containing older Honeywell and or Leeds amp Northrup instruments BINARY is probably the correct choice 19200 Baud Rate Select the rate of data transfer 9600 A800 All equipment on the link must be set to match the host 2400 setting 1200 76800 38400 NONE Parity Select the parity used if any ODD EVEN All equipment on the link must be set to match the host setting Appears for Modbus protocol only Example Decimal number 25 38 Floating point number Register 1 Register 2 Choice Byte Order Result for 25 38 FP B FP_B 0123 41 CB OA 3D FP BB FP BB 1032 CB 41 3D OA FPL FP L 3210 3D OA CB 41 FP LB FP LB 2301 OA 3D 41 CB NO Download Lockout Set to YES to prevent configuration VES from being downloaded from a PC running Honeywell SCF 18 2 UDC5300 Controller User Manual 5 00 Setting Up for Serial Communications 18 3 Setting the Communications Link Termination Jumper Introduction In order for data transfer to be successful the last unit in the communications link see Figure 4 11 must be terminated and all other slave units in the link must be unterminated Units are shipped from the factory set for unterminated operation To change the termination setting of the last unit on the link fo
258. j ariable 0 100 Bias Wiring diagram Alt Controlled soit PES LST LS StS SAS 69 Saat SITSI 1S S L2N R me ES A OREO S A EEE LO SIWE NE E EE MER 1 Al2 Wild 7 14 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Programming diagram Al1 TYPE LP1 PV LINEAR Al1 OV LP1 TYPE AO1 INP LP1 OV AO1 TYPE RATIO CAT Al2 TYPE LP1 WILD LP1 FB AO1 BC LINEAR Al2 OV 5 00 UDC5300 Controller User Manual 7 15 Using a Factory Configuration 7 4 6 Configuration 06 106 Backup to Primary Controller or PLC Uses Current Output Description This strategy provides PID control as a backup to a primary controller or PLC One analog input is used for the PV another is used to provide the value from the primary to be used as the loop s output when Remote Manual is enabled via a discrete input Each input is served by an analog input AI block The current output is supplied by a CAT type analog output AO block Basic diagram Analog Input 1 PV PID Loop 1 0 100 Output Analog Input 3 Tracking Value 0 100 Remote Discrete Input 1 Manual Status Wiring diagram AO1 Primary Controller Al1 or PLC Fault _ Relay z Analog Output 1 4 20 mA C Relay 1 End Element
259. k Data Cable Connections ccc ccecccesccessceessceesseeeesseeseseeeeeeeseseeesseeeseaees 4 16 Figure 5 1 Sample Function Block Connections seeeseeserreerrrrereererererrrrerrreerreereeererreererrreeerereereereeee 5 3 Figure 5 2 Single Loop Factory Configurations sssi R 5 29 Figure 5 3 Two Loop Factory Configurations ccccccccccccccccsssssseessseeeccecceeeeeeeeeauaaessseeeeeeeeeeeeeeeeaqaas 5 32 Proure 621 lop bevel Menu C NOI es saa an ae le ek Atcha acca Ge ad LA ed aaeeaodetadeades 6 3 Fig r 6 2 Online Mode NCIS cescsec tecen e E erne 6 4 Frisure 0 97 Program Mode Prompts tases cain cores ss Lona ater ene Sora data nds 6 6 Fisure 6 4 Maintenance Mode Prompts corssier ipa a a e ai 6 7 Proure 6 5 WDC 5300 ra a a a ie aden ts SEERNE EEN PRES taaheecensoauansndeae s 6 8 Figure 8 1 Control of Furnace Zone Temperature with 4 20 mA CAT Control Signal a 8 2 Figure 8 2 Basic Function Blocks Required for Control Configuration of Figure 8 1 eeeeeeees 8 3 Figure 8 3 Labeling Each Function Block s Name and Major Inputs and Outputs eeeeeees 8 4 Figure 8 4 Labels for Internal Function Block Parameters ccccccccccceeceeeeeeeeeeceeceeeeeeeeeeeeeeeeeeeeeess 8 4 Figure 8 5 Interconnections Between Function Blocks 0 ccccccccccceceeeeeeeecececcceeeeeceeeeeeeeeeeeeeeeeeeeeeeeeess 8 5 Figure 8 6 Complete Function Block Diagram of Figure 8 1 cececcccccccceeeeeeeeeceeceeeececeeeeeeeeeeeeee
260. k whose output value will serve as the source of the PV A number can be entered here to serve as PV during troubleshooting To use a value from a CN function block select PARM then select the Process Variable Source of the PV for the block Process Variable Low Limt PVHL Process Variable High Limit NUMBER Variable High Limit Enter the range limits for the process variable being controlled Loop tuning parameters are based on the span defined by PVLL and PVHL This value also specifies the displayed range for the operating displays Inputs that exceed these limits will cause the PV to flash on primary Process Variable Low Limit and Process displays Control Action DIR Reverse Acting Control The loop output will increase as the process variable becomes greater than setpoint and will decrease as it becomes less than the setpoint Direct Acting Control The loop output will decrease as the process variable becomes greater than the setpoint and will increase as it Control Action becomes less than the setpoint UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 8 Loop Prompt Descriptions Prompt Applies Range Selections Definition Full name To GNPB all Gain or PB Use this prompt to choose whether loop you want to specify the proportional term in the Gain or PB types control algorithm in terms of percent pro
261. l start and stop storage in numbered batches When the BT SETUP discrete is on 1 the batch number increments and storage begins When off 0 storage stops and the batch ends BT SETUP is found under DS SETUP Checking storage status DS STATS Data Storage Status Select this from the Online menu Provides status information depending on whether rollover is enabled or disabled See Table 17 8 and Table 17 9 for definitions of prompts Table 17 8 Rollover Enabled Menu Prompt Definition Full name STATUS Running or stopped TREND Rollover New data replaces older data ALARM Rollover New alarms replace older alarms EVENT Rollover New events replace older events DIAG Rollover New diagnostics replace older diagnostics SETUP Indicates DS SETUP status CURRENT Setup has not changed since last initialization NOT CURRENT Setup has changed since last initialization and number of points being stored Shown as follows 00 00 00 Days Hours Minutes SU CAP Indicates the trend capacity based on the storage rate 5 00 UDC5300 Controller User Manual 17 11 Storing Data Table 17 9 Rollover Disabled Menu Indicates the time remaining for trend storage on the memory card Based on the storage rate and number of points being stored Shown as follows 00 00 00 Days Hours Minutes Indicates the number of alarm records remaining before the memory card alarm file is full
262. language used for prompts and selections is configurable To select the language select LANGUAGE from the main Program Menu Language selections Table 9 39 lists the Language selections available when the LANGUAGE prompt is on display Table 9 39 Language Selections Selections ENGLSH English SPANSH Spanish FRENCH French ITALAN Italian 9 82 UC5300 Controller User Manual 5 00 Position Proportioning Output Setup and Calibration 10 Position Proportioning Output Setup and Calibration 10 1 Introduction Overview The controller can be programmed to provide position proportioning PP output using two relays one increase and one decrease Each relay has an associated DO block An AO block serves as the interface between the loop LP block and the DO blocks This AO needs an analog signal from an AI block for the slidewire feedback The feedback is powered by a constant 1 V from the controller s VAT output A CN block provides the input to the VAT AO block This section provides instructions for programming and wiring the controller to provide PP output In addition instructions are provided for the important final step of calibrating the output using the actual positioning device to be controlled What s in this section The following topics are covered in this section Topic Page 10 2 Configuring the Blocks Used for PP 10 2 10 3 Wiring the Controller for
263. later analysis and review Reviewing stored data requires Honeywell s SDA software on a PC Reading the PCMCIA card requires a compatible card reader available from Honeywell as P N 089435 What s in this section The following topics are covered in this section 5 00 UDC5300 Controller User Manual 17 1 Storing Data 17 2 Data Storage Setup Introduction Data storage setup consists of specifying e what process data alarm event and diagnostic information is to be saved e inthe case of batch data specifying what will trigger data storage e whether old data should be overwritten by new data Definition of event An event is a change to certain loop parameters to the instrument operating mode and to discrete inputs Event storage consists of a complete log of events including the event title time of occurrence the status or value after the change and the batch number if batch storage is used Table 17 1 shows the events that are stored Table 17 1 Events Storage Event title Event status value Setpoint choice SP1 SP2 Control action Forward Reverse Tuning Set Set 1 Set 2 Instrument Mode Online Program Maint Control Mode Auto Manual RMan SPP Start Pause Reset Setpoint 1 SP1 s value Setpoint 2 SP2 s value Control Output Loop s output value Ratio Setpoint Ratio setpoint value Discrete Input On Off Al AO Calibration Time channel t
264. le 17 4 SET TRND Prompts STRG MOD Storage Mode CONT Continuous CONT Continuous storage becomes active immediately upon initialization BATCH BATCH storage is controlled by discrete parameters defined under the BT SETUP menu Batch data may started and stopped several times in a single file until the card is full Batch start increments a batch number that is stored along with the data The batch number may be used for data retrieval and analysis using SDA software OFF OFF means no trend storage will occur EXT ENAB External Enable NONE Use this item to enable disable remote control of data storage through a discrete parameter When this discrete is high logic 1 storage is enabled when low logic 0 storage is disabled This is a separate enable from the STORAGE ENABLE menu item 17 4 UDC5300 Controller User Manual 5 00 Storing Data Table 17 4 SET TRND Prompts Prompt Range Selections Definition Full name DISABL data when the file is full old data will be lost Rollover disabled causes storage to stop when the file becomes full ROLLOVER ENABLE Rollover enabled causes new data to replace the oldest new data will be lost through 10 20 30 maximum of 3 points may be stored at the 0 25 second RATE Seconds 25 5 1 Select the storage rate for trend data storage schedule A 40 50 rate The rate selected combined with the number of points i will determine the length of time before the memory
265. le Inputs Disconnect power to all terminals More than one switch may be required to remove power 2 With the power off connect the adjustable voltage source to the terminals of the input to be calibrated Calibrating one analog input results in all in analog inputs being calibrated 3 Power up the unit 4 Go into Maintenance mode and scroll to the CALIB Al prompt Press ENTER s5 Select the input to be calibrated and press ENTER CAL 25MV will be displayed controller The message CALIB IN PROG will be displayed If the calibration is successful the Maintenance menu item CALnn will be displayed If the calibration fails because the required adjustment exceeds the acceptable range the message CALIB FAIL will be displayed 6 Adjust the voltage source to supply 25 mV then press ENTER on the 8 Continue to calibrate at 1 V and 5 V After the CAL 5V prompt the next prompt is CAL 100 this is for RTD input calibration as described in 19 2 2 9 When calibration of the input is complete power down the controller and the voltage source before disconnecting the test leads Restore the field wiring to the calibrated input with all power removed 5 00 UDC5300 Controller User Manual 19 3 Using Maintenance Mode 19 2 2 Calibrating RTD Inputs Materials required To calibrate the inputs you will need e ascrewdriver to fit the terminal blocks on the rear of the controller e a
266. llow this procedure in this sub section WARNING This procedure should be performed by qualified personnel only It is not necessary to remove power before using the button below the front panel to release the bezel latch nor before lifting the bezel out of the way on its bail linkages to access the PCMCIA card used to store data However disconnect power before using a tool to open the latches on the plate uncovered when the bezel is lifted out of the way Opening these latches provides access to the instrument assembly which slides out of the case A potentially lethal shock hazard exists if the instrument assembly is accessed while powered More than one switch may be required to disconnect power ATTENTION This equipment contains devices that can be damaged by electrostatic discharge ESD As solid state technology advances and as solid state devices get smaller and smaller they become increasingly sensitive to ESD The damage incurred may not cause the device to fail completely but may cause early failure Therefore it is imperative that assemblies containing static sensitive devices be carried in conductive plastic bags When adjusting or performing any work on such assemblies grounded work stations and wrist straps must be used If soldering irons are used they must also be grounded A grounded work station is any conductive or metallic surface connected to an earth ground such as a water pipe with a 1 2 to 1 megohm res
267. lock s output value can be read by any number of other blocks this is not a problem Be guided by the diagrams for your factory configuration so that you do not change the signal flow of the basic strategy accidentally Example adding an alarm A diagram is provided here for adding high and low alarms to factory configuration 01 101 Following this same design you can add one or more alarms to any other factory configuration If a process alarm occurs the appropriate alarm indicator on the display will light alerting the operator If you have any unused relays you configure a DO function block to use the relay to turn on an external annunciator in case of alarm AL1 INP Al1 OV AL1 ACTN DO1 INP AL1 OS HIGH DO1 AL INP Al1 OV AL2 ACTN DO2 INP AL2 OS C DO LOW Al1 TYPE LP1 INP Al1 OV LP1 TYPE AO1 INP LP1 OV AO1 TYPE LINEAR STD CAT LP1 FB AO1 BC 7 6 UDC5300 Controller User Manual 5 00 Using a Factory Configuration 7 4 Detailed Information About Each Strategy Overview The remainder of this section provides the information you need to use each strategy successfully For each strategy this section includes e abasic block diagram of the strategy this is the same as the diagram in Section 5 e a block diagram that shows the parameters and their values used to accomplish the strategy s signal flow e a wiring diagram showing the I O termin
268. lock such as an alarm AL block needs to activate a relay it does so through the DO block Each analog input signal is associated with an analog input AI block The AI function block processes the signal based on the type of input and makes the value available in a form usable by other function blocks Similarly an analog output AO block is associated with each analog output signal to be produced by the controller This AO block converts the output value calculated by the control algorithm in the loop LP block into the appropriate current or voltage output signal UDC5300 Controller User Manual 5 00 Planning In addition to serving as the interface between a loop block and hardware output terminals an AO is used in some types of discrete control Only when ON OFF control is used does the DO block interface directly with the LP block All other discrete strategies require a specially configured AO to interface between the LP and the DI for each relay used for control More information about this use of AO blocks is provided in 5 2 4 3 Configuration example Figure 5 1 diagrams an example of the way function blocks can be linked to implement a control Strategy In this example the input is a Type J thermocouple The output value OV of the analog input ATI is the process variable acted on by the loop LP1 The setpoint of the loop is 1500 The output value OV of the loop is the input of the analog output AO1 AOI makes
269. log vee Output 1 1 V Power for Slidewire Feedback Wiring diagram Alt a aor t 2 O E SHS i EOT E Sa L1 Actuator SILLESEN IST KDE L2 N Voltage SEES ENES E S OH ne CORE TRIER Er Ol V RFTER S Osis oH REN INC Al2 DEC Al3 7 52 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Programming diagram Al3 TYPE LINEAR Al1 TYPE LINEAR Al2 TYPE LINEAR 5 00 LP2 PV Al3 OV LP2 TYPE AO3 INP LP1 PV LP1TYPE LP2SPT2 CAS S LP20OV Al1 OV CAS P LP1 OV Te FB AO3 BC p4 FB LP2 BC AO3 SLWR Al2 OV CNY IN AO1 INP 20 CN9 OV AOS TYPE PP AO3 PA PP AQ3 INC DO1 AO3 DEC DO2 AO1 TYPE VAT AO1 INLL 0 AO1 INHL 100 AO1 OVLL 0 AO1 OVHL 5 UDC5300 Controller User Manual 7 53 Using a Factory Configuration 7 4 26 Configuration 26 226 Two Independent PID Loops One with Position Proportioning Relays Out and One with Direction Impulse Adjusting Relays Out Description Two independent loops each provide basic PID control For each a linear input served by an analog input AI block supplies the process variable to a standard PID loop Loop 1 uses two relays to provi
270. m Mode to Configure Function Blocks and Features 9 2 Programming Analog Inputs Introduction Each controller can support up to three analog inputs depending on the hardware options installed One is standard Each analog input is associated with an AI function block Use the prompts described in this subsection to specify the type of input to be used how the input will be converted by the controller the input range etc Analog inputs typically have a 10 over under range If the input will be used in a calculation that cannot accept a negative value or tolerate the over under range condition use the range clamp parameter CLMP to clamp low high or either direction To program Analog Inputs select PRG AI from the Main Program Menu Select the AI to program Specifying the type of input algorithm If CUST INP is enabled under FEATURES in the Program Mode Menu Section 9 12 then the first step in programming the input is specifying whether a built in input algorithm is acceptable or a custom conversion curve will be specified Table 9 1 provides information about the input algorithm types If CUST INP is disabled then the standard input algorithm prompts in Table 9 3 will be displayed as soon as an AI function block is selected for programming Table 9 1 Analog Input Algorithm Type Definitions Prompt Range Selections Definition Full Name ALGR Algorithm is used to specify the type of algorithm used by t
271. m the Online Mode Menu item and the ability to Force any DI or DO DISABL PRETUNE ENABLE Pretune DISABL removes all loop pretune menu items DISABL from the Online Mode Menu ALARMS ENABLE Alarms DISABL removes alarm configuration from the DISABL Main Program Menu Any alarms already programmed will still operate providing alarm indication and operating relays if so configured CN ENABLE Constants DISABL removes constant configuration from the Main Program Menu thus removing the ability to set or Constants DISABE adjust CN values Constants previously programmed will continue to exist DATSTR ENABLE Data Storage DISABL removes all menu items relating to Data Storage DISABL odie Orage REVIEW ENABLE Review DISABL removes the Review function from the Main Online Menu Review DISABL Programming PYROMTRY ENABLE Pyrometry DISABL removes all of the Rayotube and DISABL Spectray choices from the list of standard input type selections on the analog input programming menu 9 76 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 35 Features Prompts Prompt Range Selections Definition Full name CUST INP ENABLE Custom Input DISABL removes all custom input prompts Custom Input DISABL from the analog input programming menu 5 00 UDC5300 Controller User Manual 9 77 Using Program Mode to Configure Function Blocks and Features 9 13 Programming Secu
272. mal point to O Dedal XXX XXX the position to be used in the output value to other Output Decimal XXXX XX function blocks by the Al block Position XXXXX X XXXXXX OTEU NONE Out Engineering Units Unit of measure Fahrenheit Out Enoi E or Celsius for the output value provided provided to the Out man seng optional data strorage database Units C RJ Reference Junction Enable disable reference junction compensation Reference Junction YES Yes Enables compensation can only be used with a thermocouple if the ambient temperature is within the thermocouple s operating range NO No Disables compensation EMIS Emissivity Enable disable emissivity compensation er for EMF input Emissivity This prompt is displayed only if EMF is selected in response to SIG prompt YES Yes Enables compensation NO No Disables compensation 5 00 UDC5300 Controller User Manual 9 9 Using Program Mode to Configure Function Blocks and Features Table 9 4 Custom Al Algorithm Prompts Prompt Range Selections Definition Full Name measure with thermocouple pyrometer and RTD input D types If you change from the default F change the RGLO and RGHI accordingly The range limits will not be TMPU Temperature Unit Specifies the input value s unit of recalculated automatically F Fahrenheit C Celsius K Kelvin R Rankine NONE None Use NONE if the input is not a temperature measurement SQRT Square
273. mber and provide them to the process variable input of LP1 while measurements of the oil temperature in the jacket tank will be furnished to LP2 s PV input by AI2 Because LPI OV will provide LP2 with its operating set point LP1 s output range will be defined in engineering units of temperature instead of the usual 0 to 100 LP2 s output range is 0 to 100 in anticipation of using it to drive the AOI function block s 4 mA to 20 mA signal Note that the range covered by LP OV will have to be consistent with the operating temperature range of the oil For example if it is determined that the oil temperature will be manipulated between 75 F and 500 F the low and high limits assumed by LP1 OV and for that matter SP2 will equal 75 and 500 respectively Finally LP2 BC and AOI BC are the two back calculated feedback paths UDC5300 Controller User Manual 8 13 Learning to Create Custom Programs shown As is true for the operation of all back calculated feedback paths both LP2 BC and AO1 BC work together to acknowledge the cascaded control loops that the appropriate actions have taken place in response to both loops output values The method used to coordinate the tuning of the cascaded loops is particularly interesting Using the diagram of Figure 8 12 the first priority is to tune the secondary cascade loop of LP2 With LP1 kept in manual mode tuning may begin by first placing LP2 in manual mode and then manipulating L
274. mmed However the labels associated with DO1 s on and off state can be configured 12 12 UDC5300 Controller User Manual 5 00 Carbon Potential Option Table 12 14 AO4 Configuration for DAT Output AO4 Programming Notes TYPE DAT Our example uses time proportioned output IDPT XXXXX X Set to match the CV3 ODPT INP CV3 A2 When LP1 PV is greater than its setpoint the splitter will use its A2 output OUT DO2 The device diluting the carburizing gas should be wired to the terminals for DO2 Note that once DO2 has been assigned to work with AO3 the DO1 input and action cannot be programmed However the labels associated with DO2 s on and off state can be configured Displaying dewpoint uses another CV block If you want to have the dewpoint calculated by the CARBON type CV block available for display while the controller is online you must program a CV block as shown in Table 12 15 Then during programming of the display cycle see Section 9 select this calculated value for display on a PVCV display for the associated loop Table 12 15 CV4 Configuration to Enable Display of Dewpoint primary display for the loop but not changed by the operator CV4 Programming Notes TYPE MATH This CV block reads the dewpoint from the auxiliary output A2 of TT CVa and adds zero to it thus making the dewpoint available as the INP1 CV2 A2 CV block s output value
275. mpts The prompts displayed during AO configuration depend on the type of output specified e Table 9 10 describes each prompt used to program CAT and VAT analog output blocks e Table 9 11 describes each prompt used to program DAT analog output prompts e Table 9 12 describes each prompt used to program PP analog outputs Additional information about configuring and calibrating the controller to provide Position Proportional output is in Section 10 The prompts in each table are listed in the order in which they are displayed 9 28 UC5300 Controller User Manual 5 00 Prompt Full name Appl To Using Program Mode to Configure Function Blocks and Features Table 9 10 CAT and VAT Analog Output Prompts ies Range Selections Input Decimal Position all output types XX XXXX XXX XXX Input Decimal Position Move the decimal point to the position to be used in the input value provided to the AO block NUMBER PARM analog Input Specify the source of the input to the AO function block INPUT LOW LIMIT IN HL INPUT HIGH LIMIT NUMBER Input Low Limit and Input High Limit Specify the value of the low limit and high limit for the input to the function block If the AO s input source is a PID control loop specify a high value of 100 and a low value of 0 For other input sources specify limits using the same units as the AO s input source Variable input limits are available by
276. ms of the output as defined by input source DSLW Variable slew limits are available by programming a CN constant block s Destination with IS or DS Decreasing See Programming Constants Section 9 9 Slew Limit FSAF CAT Failsafe Specify whether or not failsafe is Failsaf VAT active in case of thermocouple failure burnout Failsafe DAT and if so which direction An input is considered to have failed when the controller detects loss of continuity or when the input is more than 10 out of range NONE None Failsafe disabled UP Up Output will go to full scale value in case of input failure upscale DOWN Down Output will go to low value in case of input failure downscale VALUE Value Select this to permit entry of a value FSV CAT OFF Failsafe Value Specify the value at which the NUMBER output will be held if input fails while FSAF VALUE The FSV value is also the initial output of the loop on cold start Failsafe Value DAT If FSV is set to OFF the output will go to 0 Value entered is in terms of the AO s input source not in terms of the output as defined by OVLL and OVHL 9 30 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 11 DAT Analog Output Prompts XX XXXX XXX XXX Input Decimal Position Move the decimal point to the position to be used in the input value provided to the AO block NUMBER PARM analog
277. mum Current l Adjusting Type Maximum Load 800 ohms maximum per CAT output Isolation 400 volts peak input output 30 volts output to GND Resolution 12 bits 0 025 VAT 2 maximum Voltage i Adjusting Type Voltage Selectable between 0 Volts and 5 Volts Minimum Load 1000 ohms Isolation 400 volts peak input output 30 volts output to GND Resolution 12 bits 0 025 DAT 4 maximum no loop dependent Duration U di i ware Adjusting Type Uses any discrete output relay Time Impulse Time 1 second to 300 seconds Proportioned Resolution 4 5 msec Minimum Off Time Off to 30 seconds Minimum On Time Off to 30 seconds Position Proportioning Uses two discrete relay outputs requires third analog input Slidewire Power Supply 1 Vdc PP 1 maximum Slidewire Resistance 100 ohms to 1000 ohms Drive Unit Speeds 10 seconds to 220 seconds DIAT 2 maximum Direction Impulse Adjusting Type Uses two discrete relay outputs Drive Unit Speeds 10 seconds to 220 seconds ON OFF 2 maximum not preconfigured for carbon control Uses any discrete relay output Adjustable Deadband 0 to 10 of span 5 00 UDC5300 Controller User Manual 2 5 Specifications and Model Number Table 2 1 Specifications continued Discrete Inputs Outputs Inputs Number 0 2 or 3 Type Dry contact actuation Input Level 24 Vdc 15 mA internally supplied Isolation 30 volts point to ground Relay outputs Number
278. n Proportioning Relays for Cool Description This PID loop with split output provides a current output to one actuator when the process variable is above setpoint When the PV is below setpoint two position proportioning relays control a different actuator The split output is achieved with a calculated value CV function block programmed to be a standard splitter A control deadband is configurable An analog output AO block with both its type and its positioning algorithm set to PP position proportioning interfaces between the loop LP block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO block is not associated with analog output terminals The analog feedback signal from the positioner s slidewire is received at AI2 The feedback is powered by a constant 1 V from the terminals associated with AOI and its VAT voltage adjusting type AO function block having an output range from 0 to 5 Because the input to the AO is 20 from a constant CN block a steady 1 V out is achieved 20 of the 5 V range Basic diagram HEAT p Analog Output 2 p 4 20 mA Analog Input 1 i on fae a SE Relay 1 0 100 COOL a A DEG Relay 2 Position Analog Input 2 Proportioning Slidewire Feedback 0 100 Analog Output 1 1 V Power to Slidewire Feedback 7 12 UDC5300 Controller User Manual 5 00
279. n Probe mV Output provided by PBIN input Oxygen Probe Temperature provided by TPIN input CO Compensation provided by CO parameter Control Corp 0 10 to 1 40 0 35 to 1 65 1054 to 1219 mV mV 0 20 to 1 40 1037 to 1224 mV 5 00 Super Systems information is based on an equation but no tabular data these limits are based on typical probe limits Table 12 2 Probe Manufacturers Valid Working Ranges PARAMETER VALID WORKING RANGE All Probe Types Output of the C calculation before addition of the value of the FURN furnace factor parameter UDC5300 Controller User Manual 12 3 Carbon Potential Option 12 3 CARBON Type CV Prompts Introduction When CARBON is specified as the type during configuration of the CV block as described in Section 9 the prompts in Table 12 3 are available for configuration Input Decimal Position Output Decimal Position Probe Type Input Temperature Units 12 4 Table 12 3 CV Carbon Potential Prompts XX XXXX XXX XXX XXXX XX XXXXX X XXXXXX XX XXXX XXX XXX XXXX XX XXXXX X XXXXXX NONE AACP FCC MARTHN SUPSYS NUMBER PARM analog NUMBER PARM analog Input Decimal Position Move the decimal point to the position used by the inputs to the CV block the position to be used in the output values provided Output Decimal Position Move the decimal point
280. n a factory configuration is loaded the function blocks needed to implement the strategy are automatically programmed to pass the required data In addition the internal parameters in each function block used by the strategy are set to do the job required For example if the basic single loop PID strategy with CAT output is selected an loop block s internal parameters are set to perform PID control The loop s input is programmed to read the output of the analog input block associated with the terminals where the field signal comes in The loop s output is used by an analog output block This is accomplished by the AO block s input pointing to the loop s output The analog output block type is set to CAT so that it makes the appropriate current output signal available at the output terminals connected to the controlled device Availability of factory configurations All factory configurations are stored in the firmware of every UDC5300 controller although not every controller has the I O hardware to support every strategy How a factory configuration is used If you specified a factory configuration during model selection see Section 2 then the correct strategy will be loaded into memory before the unit is shipped All that will be left for you to do is program site specific values such as display ranges and tuning parameters If you did not specify a factory configuration or specified the wrong one you can load a different fac
281. n addition to using the A and V keys to advance a running but held profile to a different segment as described above the A and V keys can be used to advance a stopped profile so that it starts at a segment other than 1 11 12 UDC5300 Controller User Manual 5 00 12 1 Carbon Potential Option 12 Carbon Potential Option Introduction Overview When the carbon potential option is selected see model selection guide in Section 2 a CARBON type CV calculated value block is available This block provides a C output value useful in applications such as e carburizing increasing the carbon content of the surface of low carbon steel e hardening heat treating carburized parts e atmosphere generating applications This section describes the CARBON type CV block s inputs outputs and internal parameters It also provides important information about using this block with other types of blocks to provide carbon control What s in this section 5 00 The following topics are covered in this section Topic Page 12 2 Functionality 12 2 12 3 CARBON Type CV Prompts 12 4 12 4 Application Notes 12 6 UDC5300 Controller User Manual 12 1 Carbon Potential Option 12 2 Functionality 12 2 1 Actions Performed Overview The CARBON type CV block will perform the following actions Produce a value output OV which represents the percent carbon C present in a furnace atmosphere based on
282. n also be disabled constant values e on off status of any DI or DO and alarm setpoints the capability to force the state of DI and DO parameters can be disabled in Program mode using FEATURES e analog input value the capability to change AI values disabled in Program mode using FEATURES e analog output value the capability to tune AO values The prompts available when DATA ENT is selected from the Online menu are shown in Table 15 8 ATTENTION The FORCE feature can be disabled in Programming mode If it has been disabled it will not appear as a prompt under DATA ENT The procedure for changing alarm setpoints is in Table 15 9 The procedures for using other data entry functions parallel that for changing alarm setpoints Table 15 8 Data Entry Prompts The setpoint will be displayed Press ENTER to access it Adjust with the A and W keys Press MENU to leave the menu Press ENTER to access it Adjust with the A and V keys Press MENU to leave the menu Prompt Range Selections Full name ALARM Select an alarm to adjust CN Select a Constant to Constant ae FORCE FORC DI FORC DO Select FORC DI or FORC DO to force the change of state of any DI or DO After selecting a DI or DO its current state will be displayed Press ENTER to show the forced state An unforced DI or DO will display RELEAS a forced DI or DO will display F OFF or F ON Press ENTER to ac
283. n out Impulse Adjusting Type output 25 In 3 analog Loop 1 CAS_P Loop 1 analog PV PP VAT output cascade PID with 225 Out 1 voltage provides position 2relays Loop 2 CAS_S Loop 2 analog PV constant 1 V proportioning relays to power out ang slidewire analog slidewire feedback feedback from positioner 26 In 3 analog Loop 1 STD Loop 1 analog PV Loop 1 PP VAT output two independent 226 Out 1 voltage standard PID provides PID loops one 4 relays kar BEDE and Loop 2 DIAT constant 1 V position OOP lt oe i to power proportioning relays ioe ae ree slidewire out and one with irection nice positioner feedback DIAT relays out Adjusting Type output Loop 2 analog PV 27 In 2 analog Loop 1 DIAT Loop 1 analog PV Loop 1 DIAT two independent 227 Out 4 relays PID with PID loops both Direction Loop 2 analog PV Loop 2 DIAT with DIAT relays Impulse out Adjusting Type output Loop 2 DIAT 28 In 2 analog Loop1 ON OFF Loop 1 analog PV Loop1 ON OFF two independent 228 Out 2 relays loops each with Number identifying the strategy when loading as described in Section 7 xx Number in Table I of Model Number Breakdown see Section 2 5 28 UDC5300 Controller User Manual 5 00 Planning PV 20 mA Analog Analog Input 1 aR N Output 1 4 0 100 p A Configuration 01 101 PID with Current Output Analog HEAT Output 1 4 20mA Analog Input 1 PM He 1 GAS Analog 0 100 COOL Outpu
284. n the furnace atmosphere PARM analog The default is 20 FURN OFF Furnace Factor The value of FURN will be added to CO OFF Carbon Monoxide Compensation Specify the Compensation NUMBER the calculated C before the value is made available Furnace Factor NUMBER as CVn OV PARM analog Use this furnace factor to compensate for sensor location or other variables The default is 0 0 SOOT OFF Sooting Factor When SOOT ON the anti sooting factor provided at output A1 will be based linearly on Sooting Factor OI the probe temperature When SOOT OFF the value of output A1 will be 2 0 If SOOT ON a probe temperature lt 1408 F limits C output OV to 0 75 and a probe temperature gt 2086 F limits OV to 2 0 See 12 4 for an example of an application using the anti sooting factor as the setpoint high limit of a control loop HYDR range 0 to 100 Percent Hydrogen Specify the percentage of hydrogen in the gas used for carburizing This value is used in the calculation of the dewpoint value for output A2 The default is 40 5 00 UDC5300 Controller User Manual 12 5 Carbon Potential Option 12 4 Application Notes 12 4 1 Overview Introduction The CARBON type CV block is intended to be used with other function blocks to provide a complete control solution The configuration described in this subsection is only an example other configurations can be accomplished For example the sec
285. nction Blocks and Features Table 9 29 CV Advanced Splitter Prompts Feedback 1 FB2 Feedback 2 FB3 Feedback 3 NUMBER PARM Feedback 1 Feedback 2 and Feedback 3 Specify the source of the back calculation value BC of the analog output assigned to the A1 output Feedback 1 A2 output Feedback 2 and A3 output Feedback 3 A1 Input Low Limit IH1 A1 Input High Limit NUMBER A1 Input Lower Limit and A1 Input High Limit When input is within the range defined here the A1 output is scaled between OL1 and OH1 A1 Output Low Limit OH1 A1 Output High Limit NUMBER A1 Output Lower Limit and A1 Output High Limit Specify the scaled range for A1 A2 Input Low Limit IH2 A2 Input High Limit NUMBER A2 Input Lower Limit and A2 Input High Limit When input is within the range defined here the A1 output is scaled between OL2 and OH2 A2 Output Low Limit OH2 A2 Output High Limit NUMBER A2 Output Lower Limit and A2 Output High Limit Specify the scaled range for A2 9 62 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 29 CV Advanced Splitter Prompts A3 Input Low Limit IH3 A3 Input High Limit NUMBER A3 Input Lower Limit and A3 Input High Limit When input is within the range defined here the A1 output is scaled between OL3 and OHS A3 Output Low Limit OH3
286. nd 1 i cee tional an indirect source is specified as in an adaptive gain configuration the value can only be altered at the source Variable Gain1 or PB1 is available by programming a CN constant block s Destination with GN or PB See Programming Constants Section 9 9 To allow integral only control select OFF 5 00 UDC5300 Controller User Manual 9 17 Using Program Mode to Configure Function Blocks and Features Table 9 8 Loop Prompt Descriptions Prompt Applies Range Selections Definition Full name To RST1 all OFF Reset in Repeats per Minute Specify how many times proportional action should be Reset 1 NUMBER repeated per minute first set of tuning except range is 0 005 to parameters This is the integral component of ON_OFF 99 99 repeats per control minute Reset adjusts the controller s output taking into consideration both the size of the deviation SP PV and the duration of the deviation The amount of corrective action depends on the value of PB1 or GAIN1 Enter a starting value at initial configuration The value may be altered online for final loop tuning Variable reset 1 is available by programming a CN constant block s Destination with RS See Programming Constants Section 9 9 To allow proportional only control select OFF When reset is turned off the MRST manual reset value determines the loop output at setpoint Bumpless manual to automatic transfer is cancelle
287. nd control the temperature of the furnace zone to a local set point of 500 F Using a 4 mA to 20 mA signal applied to a gas valve actuator the furnace zone s temperature will be controlled by regulating the flow of gas to the zone s burner The instrument will measure temperature in a range between O F and 1000 F by means of a Type J thermocouple To support this application a 4 mA to 20 mA control loop with a thermocouple process variable must be configured Three function blocks one for specifying a thermocouple analog input a second for a standard PID control loop and a third defining a 4 mA to 20 mA analog output are needed to produce this control strategy s function block diagram Each function block should first be arranged as in Figure 8 2 Analog input and output function blocks are represented by right pointed triangles Control loop function blocks are represented by right pointed parallelograms 8 2 UDC5300 Controller User Manual 5 00 Learning to Create Custom Programs ANALOG INPUT CONTROL LOOP ANALOG OUTPUT Figure 8 2 Basic Function Blocks Required for Control Configuration of Figure 8 1 2 Label input parameters Properly label each function block First assign to each function block a name that identifies it within the hardware and feature capacities of the instrument being worked with You may assign any of the analog inputs control loops and analog outputs that your instrument has to the bl
288. nd loading 16 1 16 6 carbon monoxide compensation 12 5 5 00 UDC5300 Controller User Manual Index 1 Index carbon potential CV functionality 12 2 12 4 programming for sample applicaiton 12 6 12 10 prompts 12 4 12 6 carburizing 12 1 cascade control and factory configuration 7 5 example 8 12 selecting 9 14 CAT output DIP switch settings 20 1 20 5 example 8 3 programming 9 29 9 30 CFG FILE Program menu prompt 16 4 CHGA LP parameter 9 25 CKHI AI custom parameter 9 10 CKHI AI standard parameter 9 5 CKLO AI custom parameter 9 10 CKLO AI standard parameter 9 5 CKUN AI custom parameter 9 10 CKUN AI standard parameter 9 5 cleaning the front panel A 1 clearing memory 19 7 CLMP AI standard parameter 9 6 clock See time CMPT AL parameter 9 68 CN DATA ENT prompt 15 11 CN FEATURES prompt 5 36 9 76 CN block description 5 13 parameters 9 69 9 72 used to display and change value 12 9 CO CV CARBON parameter 12 5 cold start 19 8 commissioning hints 13 6 communications See serial communications COMP Pretune prompt 13 4 compare CV 9 64 9 66 condition time 9 47 9 65 condition type 9 46 9 65 configuration clearing 19 7 storing and loading 16 1 16 6 constant block See CN block constants displaying and changing 14 4 programming 9 69 9 72 continuous data storage 17 4 control action in factory configuration 7 5 control loops See loops copying a
289. nd other internal parameters not listed in this table as appropriate for your site See Section 9 for a complete list of SPLIT type LP parameters Table 12 10 LP1 Configuration for Control of Carburizing Gas TYPE SPLIT The loop must be a SPLIT type to implement our split output in the example If another type of output is used change the type However the loop cannot be a standard PID STD because the STD type does not support the required RMAN and OTRK parameters IDPT XXXXX X Set the decimal point to match CV2 ODPT ODPT XXXXX X Set the decimal point to the appropriate position PV CV2 OV The process variable will be the C value calculated by the CARBON type CV block SPHL nnn Enter some number for the setpoint high limit This number will be overwritten at runtime by the dynamic value from CN3 as described below Do not set the limit to OFF FB CV3 BC Every loop must receive feedback In this case the feedback will come from the back calculation value of CV3 the standard splitter If OTRK and RMAN are to be used to clamp the output at 0 0 until the furnace temperature reaches CV2 TPLL you must specify a value of 0 0 not OFF or some other value for OTRK The 0 0 is not the default You must specify that LP1 RMAN CV2 OS the discrete that will have a value of 0 until CV2 TPIN CV2 TPLL CN block required to provide dynamic setpoint high limit based on sooting factor 5 00 The SP
290. ndent PID Loops Each with Current Output Analog Input 1 Analog Output 1 py PID p Loop 1 0 100 4 20 mA Analog Input 2 sii N PV Loop 2 C Relay 1 0 100 Time Prop Configuration 18 218 Two Independent PID Loops One with Current Output and One with Time Proportioned Relay Out Analog Input 1 E Analog Output 2 PV Loop 1 0 100 eg PANER INC Analog Input 3 a a Analog Output 3 oe ney PID PV Loop 2 0 100 DEC Relay 2 Position Proportioning Analog Input 2 Slidewire si Feedback Analog 2 oes Output 1 1 V Power for Slidewire Feedback Configuration 19 219 Two Independent PID Loops One with Current Output and One with Position Proportioning Relays Out Figure 5 3 Two Loop Factory Configurations 5 32 UDC5300 Controller User Manual 5 00 Planning Analog Input 1 PID Analog Output 1 V Loop 1 2 0 100 J 4 20 mA INC Analog Input 2 X Relay 1 PID V Loop 2 0 100 DEC Relay 2 DIAT Configuration 20 220 Two Independent PID Loops One with Current Output and One with Direction Impulse Adjusting Relays Out PV PV Analog Input 2 0 100 PID Analog Input 1 PID Loop Reay 1 0 100 Loop 1 Time Prop l Configuration 21 221 Cascade PID with Time Proportioned Relay Out 2 0 Relay 1 Time Prop
291. ndependent PID Loops Each with Time Propornoned Rey OT Error a tanec seated ooh tueat tdi eeamenteede 7 46 7 4 23 Configuration 23 223 Two Independent PID Loops One with Time Proportioned Relay Out and One with Position Proportioning Relays Out 7 48 7 4 24 Configuration 24 224 Two Independent PID Loops One with Time Proportioned Relay Out and One with Direction Impulse Adjusting Relays Out 7 50 7 4 25 Configuration 25 225 Cascade PID Position Proportioning Relays Out 7 52 7 4 26 Configuration 26 226 Two Independent PID Loops One with Position Proportioning Relays Out and One with Direction Impulse Adjusting Relays Out 7 54 7 4 27 Configuration 27 227 Two Independent PID Loops Each with Direction Impuls Acjus tine REMY SOU tes alle eter ele een tnd deteutenaced aatedseltntllaetaauia selenite de 7 56 7 4 28 Configuration 28 228 Two Independent Loops Each with ON OFF Relay 7 58 8 LEARNING TO CREATE CUSTOM PROGRAMS M G eee 8 1 8 1 OASE RY E cu ESSEN ieee hase caso E E NES SARESSS SEE E E E ERE cas eee SERENE USS ENSURE ENES 8 1 8 2 Programming a Current Driven Heat Treat Element cccccccccccceceessseeseeeeeeeeeeeeeeenaas 8 2 8 3 Time Proportioning Relay Driven Pump keseser d e E 8 7 8 4 SOLE ODF or DUPIE N CONTO 5 aa en eer eceteren nr onenrsret rraneny nearer en nr nale tiet ene nae 8 9 8 5 Cascade Contro Paarse cae SS Ra moa ye BESES
292. nding to errors resulting from changes to DIAT setpoint The algorithm will adjust its Reset SPLIT Integral term to a value required to maintain the present output when the setpoint is changed Normal proportional action should occur for all changes and variations to the controlled variable be used to define a deadband above and below inysteresis eee the setpoint If the PV varies from the setpoint range is 0 to while the output is ON but by less than the value 100 of PV span specified here the output will remain ON HYST ON OFF OFF On OFF Hysteresis The value entered here will preventing excessive output oscillation 9 22 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 8 Loop Prompt Descriptions Range Selections MOFF entered here or read from the selected parameter causes the control output to OFF The control output will remain OFF until MOFF or the parameter to which it points goes to a logic low 0 If configuring On Off loop skip to LBAD ON OFF Manual Off A logic high 1 value for last prompt in table after configuring MOFF NUMBER PARM analog feedback or enter a number during troubleshooting Feedback provides verification to the loop that the loop output value LP OV was processed by the analog output block AO The source of feedback is typically the associated Back Calculation Value BC of the analog outp
293. nfigure one segment beyond the last segment used by your control strategy The VAL of this final segment should be set to the same value as the last real segment The TIM of the last segment should be set to OFF For example suppose your process requires a profile with twelve segments and that the twelfth segment must be a soak with a VAL of 50 Configure S12 VAL 50 but also configure S13 VAL 50 and set S13 TIM OFF Any other value for 13 VAL will result in segment 12 being a ramp as the controller tries to accommodate the transition to the different S13 VAL If all sixteen segments are programmed and S16 TIM does not equal 0 then the profile will behave as if a seventeenth segment exists This pseudo segment will be a ramp up or down to 0 The time will be the same as S16 TIM UDC5300 Controller User Manual 5 00 5 00 Configuring and Using Setpoint Profiler 1 hour 600 500 400 300 200 100 Segment 1 Segment 2 Segment 3 Segment 4 Value 100 Value 500 Value 500 Value 300 Time 2 hours Time 1 hour Time 2 hours Time OFF Figure 11 1 Sample Setpoint Profile UDC5300 Controller User Manual Configuring and Using Setpoint Profiler 11 5 Storing and Loading Profiles Introduction If the controller includes the Data Storage feature setpoint profiles may stored on a removable SRAM PCMCIA card for archiving or for transferring the profile to other controllers Stored profil
294. ng Program Mode to Configure Function Blocks and Features Table 9 17 CV Peak Picking Prompts Prompt Range Selections Definition Full name RNGL Numerical range Range Low Limit and Range High Limit Enter the outputs range when displayed as a trend with Range Low Limit Honeywell SDA software RNGH These limits do not clamp or flash the output s Range High Limit display on the controller 9 40 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 7 2 CV Signal Select SSEL Introduction The signal select operation selects the value of one or more of its inputs and makes it available as CVn OV based on the action specified using the ACTN prompt CV signal select prompts Table 9 18 describes the Signal Select prompts Table 9 18 CV Signal Select Prompts Prompt Range Selections Definition Full name IDPT XX XXKX Input Decimal Position Move the decimal point to XXX XXX the position used by the inputs to the CV block Input Decimal XXXX XX Position XXXXX X XXXXXX ODPT XX XXXX Output Decimal Position Move the decimal point to XXX XXX the position to be used in the output value provided by Output Decimal XXXX XX the CV block Position XXXXX X XXXXXX OTEU OFF Output Engineering Units Specify the unit of measure Fahrenheit or Celsius for the output Output F Engineering Units C INP1 OFF Input Source 1 through Input Source 8 Use these
295. ng Setpoint Profiler 11 1 Introduction Overview The optional Setpoint Profiler produces a time varying setpoint for a loop s Setpoint 2 Setup and configuration are done through a Program mode menu PRG SPP and an Online mode Menu PROFILE Online operation is controlled through two menus one is accessed by pressing the SETPOINT PRGM key the other appears in the Online Mode Menu SP PRFLR only when a profile is active What s in this section The following topics are covered in this section Topic PERE 11 2 Description Z oOo le 11 3 Defining the Profiler Inputs and Range ee 11 4 Setting Up a Profile 11 5 11 5 Storing and Loading Profiles i 11 6 Using a Setpoint Profile ee 5 00 UDC5300 Controller User Manual 11 1 Configuring and Using Setpoint Profiler 11 2 Description Configurable elements The Setpoint Profiler supports up to sixteen segments During configuration of a profile the value and time at that value are specified for each segment If the next segment s value is the same as the current segment s value the current segment s time will specify a SOAK time at that value If the next segment s value differs from the current segment s value the profile output will RAMP to the next value in the current segment s time The time base for all profile segments may be set to HOURS MINUTES or SECONDS In addition for each segment the ON 1 or OFF 0 state of each o
296. nger be present in the online displays To delete the INPUT FAILURE message from the summary of diagnostics go to the Online menu and select SUMMARIES then select DEL DIAG What to do if transmitter out of range condition is normal If a transmitter out of range condition is normal for your application and the latched diagnostic is undesirable clamp the input value at the range limits preventing the input diagnostic failure To do this go the Programming mode and select the input s AI block In response to the CLMP prompt select LO RNG to limit underrange input HI RNG to limit overrange input or RANGE to limit both overrange and underrange input values Other results of input problems During power up if an analog input is open or is out of range the setpoint and process variable values will display OFF and the loop s AUTO mode is disabled Check connections to determine problem During calibration if the input reference voltages supplied by the technician are outside acceptable limits a CALIB FAIL message will be generated 5 00 UDC5300 Controller User Manual 21 3 Messages Internal fault messages In addition to diagnostic messages internal fault messages are presented to indicate a hardware problem Table 21 2 lists the probable circuit card associated with error condition Table 21 2 Internal Fault Messages Diagnostic Meaning Suspected Hardware NONV RAM ERROR EEPROM Problem CPU
297. nsfer from Manual to Automatic Modes Loop Bad Action Required Specify whether the operator must take action to return the loop to normal operation after a loop block has gone to failsafe because of an abnormal loop condition See Table 21 3 NO No operator action needed to return the loop to normal operation when the abnormal condition has been cleared Yes Operator action needed 5 00 Using Program Mode to Configure Function Blocks and Features 9 4 Programming Analog Outputs Introduction Each analog output AO function block serves one of two purposes If your strategy uses Current Adjusting Type CAT or Voltage Adjusting Type VAT control output that is if the field device being controlled needs an analog signal then the AO block is the interface between the control loop and the actuator in the field For this purpose one AO block is associated with each hardware analog output Depending on the model purchased the unit can support one or two hardware outputs AOI is associated with hardware output 1 AO2 is for hardware output 2 See terminal label on controller case If your strategy uses Duration Adjusting Type DAT or Position Proportional PP control output then the AO block serves as an intermediary between the control loop and the discrete output blocks serving the relays that are wired to the controlled device DAT uses one relay PP uses two Although AO2 can be associated with an actual
298. nt polycarbonate plastic bezel and scratch resistant lens Dimensions Bezel 96mm H x 96 mm W 3 78 in H x 3 78 in W Case 92mm H x 92 mm W x 192 mm D 3 62 in H x 3 62 in W x 7 55 in D Temperature Operating 0 C to 55 C 82 F to 131 F Storage 10 C to 70 C 14 F to 158 F Relative Humidity 10 to 90 non condensing at 40 C Altitude lt 2000 meters Vibration Level 5 Hz to 15 Hz 1 mm displacement 15 Hz to 150 Hz 0 5 g acceleration Power Universal supply 85 Vac to 265 Vac 50 60 Hz 18 VA Fuse Rating 1 0 amp 250 Vac fast acting type not replaceable by operator 2 2 UDC5300 Controller User Manual 5 00 Specifications and Model Number Table 2 1 Specifications continued Canadian and International IEC CENELEC CE standards for intended instrument locations This product is designed and manufactured to be in conformity with applicable U S The following Standards and Specifications are met or exceeded European Council Directives 73 23 EEC the Low Voltage Directive and 89 336 EEC the EMC Directove Conformity of this product with any other CE Conformity This product is in conformity with the protection requirements of the following CE Mark Directive s shall not be assumed For Canada CAN CSA C22 2 No 1010 1 92 Safety For US ANSI ISA S82 1994 For Europe EN61010 1 Product Class I Permanently Connected Panel Mounted Industrial Co
299. ntrol Equipment Classification with protective earthing grounding EN61010 1 Terminals must be enclosed within the panel Front panel IP52 NEMA 12 With the proper mounting and the front bezel firmly closed the UDC5300 meets the criteria for NEMA 12 Type enclosures for protection from falling dirt Enclosure Rating Panel Mounted Equipment IP 00 this controller must be panel mounted and dripping water from the front of the panel See Fig 3 1 for mounting Rear of Panel IEC 529 IP 20 EN 60529 IP 20 Installation Category Il Energy consuming equipment supplied from the fixed installation Category Local level appliances and Industrial Control Equpment EN 61010 1 Overvoltage Category Pollution Degree 2 Normally non conductive pollution with occasional conductivity caused by condensation Ref IEC 664 1 EMC Group 1 Class A ISM Equipment EN 55011 emissions Industrial Equipment EN 50082 2 immunity Method of EMC Assessment Declaration of 51197705 Conformity Flammability UL 94 V2 Rating 5 00 UDC5300 Controller User Manual 2 3 Specifications and Model Number Table 2 1 Specifications continued Attributes Display Fixed segment vacuum fluorescent alphanumeric A six character upper display dedicated to the process variable 4 digits Alternate information displayed during configuration mode An eight character lower display primarily shows key selected op
300. nts down UDC5300 Controller User Manual 5 00 5 00 Learning to Create Custom Programs Note the function block diagram s use of three back calculated feedback paths Two such paths are labeled AOI BC and AO2 BC They are connected to CV1 from the analog output function blocks at inputs denoted FB1 and FB2 CV1 BC the third feedback path runs from CV1 to the FB input of LP1 All three feedback paths work together to acknowledge to LP1 that the appropriate output signals have been generated in response to the output levels the loop has called for UDC5300 Controller User Manual 8 11 Learning to Create Custom Programs 8 5 Cascade Control Introduction 8 12 An example of a cascade control application is featured in Figure 8 11 Cascade control is typically used when two process values must be simultaneously controlled with one process value directly influencing the behavior of the other In this control strategy each process value is supported by its own dedicated control loop The term cascade is used because it describes how this control approach literally attaches both control loops together This act of linking control loops allows for the regulation of both process values using one and only one output control signal CONTROLLER THERMOCOUPLES REACTION PV 200 SP 500 OUT 83 5 4 TO 20 mA CAT ELECTRIC HEATING aE Door egg ELEMENT AC POWER SOURCE Figure 8 11 Temperature Control of
301. o 59 seconds Period Seconds This prompt is displayed if PHSE DAILY Specify the number of seconds in the period Period Seconds EGEN ij an range is 00 to 31 MNTHLY or WEEKLY Specify the day component of Start Day the Start Time M PRSE WEEKLY then When PHSE MNTHLY If SDAY exceeds the choices are days of the SDAY if PHSE MONTHLY then Start Day This prompt is displayed if PHSE number of days in a particular month then the discrete ween switches to 1 on the last day of that month For example if SDAY 31 then the discrete will go to 1 on 30 September SHR range is 0 to 23 hours Start Hours This prompt is displayed if PHSE MNTHLY WEEKLY or DAILY Specify the hour Start Hours component of the Start Time SMIN range is 0 to 59 minutes Start Minutes This prompt is displayed if PHSE MNTHLY WEEKLY or DAILY Specify the minute Start Minutes component of the Start Time MNTHLY WEEKLY or DAILY Specify the seconds component of the Start Time RST OFF Reset This prompt is displayed if PHSE NONE SSEC range is 0 to 59 seconds Start Seconds This prompt is displayed if PHSE Specify the discrete to be used as the Reset trigger or 0 enter a discrete value directly here 5 00 UDC5300 Controller User Manual 9 57 Using Program Mode to Configure Function Blocks and Features 9 7 8 CV Inverter INV Introduction For this type the output CVn OS is the logical inverse of th
302. o Control Time Proportioning Relay Output Specify Table Ill 3 Position Proportioning Output Specify Table Ill 3 Ratio Control Position Proportioning Output Specify Table III 3 Backup Control Position Proportioning Output Specify Table III 3D Time Proportioning Relay Output Controller Position Proportioning Output DIAT 3 Position Step 104 105 106 107 108 109 110 2 10 UDC5300 Controller User Manual 5 00 TABLE I Continued DUAL LOOP Specifications and Model Number No Preconfiguration Factory Defaults Specify Table Ill 3 cascade Control 4 20 mA Output Specify Table Ill 3 2 Loops 4 20mA and 4 20mA Specify Table III 3C 2 Loops 4 20mA and Time Prop Relay Output Specify Table III 3 2 Loops 4 20mA and Position Proportioning Output Specify Table Ill 3C 2 Loops 4 20mA amp Position propportioning Output DIAT 3 position step Specify Table Ill 3 Cascade Time Proportioning Relay Output Specify Table Ill 3 2 Loops Time Proportioning Relay amp Time Proportioning Relay Outputs Specify Table Ill 3 2 Loops Time Proportioning amp Position Proportioning Outputs Specify Table Ill 3D 2 Loops Time Proportioning amp Position Proportioning DIAT Outputs Specify Table Ill 3D Cascade Position Proportioning Output Specify Table III 3 2 Loops Position Proportioning amp DIAT Position Proportioning Outputs S
303. o change the loop setpoint online Avoid changing connected values Al is custom type but X does not increase by at least 0 00001 Al is custom type but Y does not change by at least 0 00001 5 00 UDC5300 Controller User Manual 21 9 Messages 21 10 UDC5300 Controller User Manual 5 00 Parts List 22 Parts List Introduction All replacement parts for the instrument are consolidated into the replacement parts kits described below The parts in the kits are shown in the figures referenced in the kit descriptions The numbers at the left below identify the kits in the drawings To obtain a particular replacement part order the appropriate kit using the eleven digit Kit Part Number shown in the table Kit numbers and descriptions Kit includes 222 1 Auminumcae 22 2 2 Case Sub Bezel i 22 2 44 Shel Seal Gasket i 22 2 25 Sub bezel Screws 4 22 4 3 Case Rear Screws 4 22 4 5 Reference Junction Bushing i 22 4 6 Reference Junction Bushing Retainer 22 4 7 Case Rear Cover i 22 4 8 Rear Terminal Boards D 22 4 24 Ground Bus Bar i 224 43 Cover Plate HEFE Kit Includes Figure Detail Part Description Quantity 22 2 4 Complete Display Assembly Includes Membrane 1 Keypad 5 00 UDC5300 Controller User Manual 22 1 Parts List Kit includes Figure Detail Part Description
304. o clear the stop then the entire assembly can be 3 The assembly will strike a stop when it is almost all the way out Lift the back removed There are no cables to be disconnected the right side when facing the case See Figure 18 2 To terminate a controller jumpers W2 and W3 must both be set to the 1 2 position 4 When present the serial communications card p n 046925 is in Slot 1 on To remain unterminated jumpers W2 and W3 must be in the 2 3 position 5 After setting the jumpers put the rear of the card cage assembly into the case connectors When the assembly is correctly positioned the two latches will 6 Press the instrument assembly back to fully engage the rear card edge Snap into place 7 Pull on the bail to verify that the assembly is fully seated and firmly latched then swing the bezel down into position 8 Engage the top edge of the bezel first then swing in the bottom and press in until the button latch snaps into place Do not power up the unit until the instrument assembly has been replaced and the assembly latches are firmly hooked UDC5300 Controller User Manual 5 00 Setting Up for Serial Communications ATTENTION ae eee ma Latch Lever Figure 18 1 Releasing Latch Levers Location Card Slot 1 i O i ji a E
305. o shaceishesdd caste iasharedeende a e 11 7 Figure 12 1 Diagram of Carbon Potential Configuration Example ccccccccccccccccceceeceeeeeeeeeeeeeeaees 12 7 Figure 14 1 Example Of A Primary Displiyessnirenteseinin e a ee al ea E Dae 14 3 xiv UDC5300 Controller User Manual 5 00 Figure 16 1 Figure 18 1 Figure 18 2 Figure 20 1 Figure 20 2 Figure 22 1 Figure 22 2 Figure 22 3 Figure 22 4 Figure 22 5 5 00 ba rans A VICTORY aid BESBEREERSES ER SS FESD ER REBES SE SER DES LES A SED REEE 16 3 I SOS ere CV ay ea Bee OVO een eee at eae CS ELSE ROI a eT RCL DEER ea ec EDEN ERE ER 18 5 Location Of Termination Jumpers W2 And W3 ccccccccccccccccecesssssseeeeeeeeeeeeeseeeeeaaaaaeeees 18 5 Releasine Fate Ben cs gs oss ee eran oer ee rene ne ey re eee ten nr eee a 20 5 OCIO OFS SWI Ne Ss ich ec ne ne nere ele ne en eden watencaeeoeeeesesoemtecmarnece 20 5 Instrument Panel Mounting HardWare nerie E 22 7 Instrument Card Cage Removed From Case along with Sub Bezel and Gasket 22 8 Exploded View or Instrument s Display esmane 22 9 Components of Instrument Rear Assembly tried LA i a aa 22 10 Exploded View of Instrument s Card Cage ccccccccccccccsssssssseeseseeeeeeceeeeeeeseseaaaaeseeeeees 22 11 UDC5300 Controller User Manual XV Xvi UDC5300 Controller User Manual 5 00 1 1 Introduction 1 Introduction Features and Benefits Versatile instrument The UDC5300 controller offers flexibility
306. ock receiving the PV Program the loop s feedback to be read from the AO block interfacing between the loop and the discrete outputs In our example LP1 TYPE STD LP1 PV All OV LP1 FB AO3 BC e If SPLIT is used a CV calculated value block must be configured as a standard splitter and additional AO and DO blocks are used Use factory configuration 04 as an example See Section 7 e f CAS_P cascade primary is used you must also configure the secondary loop as CAS_S Use factory configuration 25 as an example See Section 7 e f you want the controller to use DIAT output if the slidewire feedback fails the loop type must be DIAT the AO s type must be PP and the AO s positioning algorithm must be AUTO The AUTO DIAT operation uses a differential increment or decrement routine when in manual mode Example To change from 50 to 60 output 50 output will be initially displayed Pressing the increment button will cause the display to increment from 0 to the desired differential 10 When the button is released the display will change back to 50 output and the actuator motor will drive to the desired 60 output 5 00 UDC5300 Controller User Manual 10 3 Position Proportioning Output Setup and Calibration Table 10 1 Block Configuration to Implement PP Shown in Figure 10 1 4 Program the block associated with the hardware output providing the voltage to power the slidewire feedback This must be a VAT
307. ocks comprising the function block diagram drawn For simplicity AI1 LP1 and AOI will be used in this example Refer to Figure 8 3 Note that AIS LP2 and AO2 could just as easily have been used 3 Label output parameters 5 00 The second part in labeling each function block is to denote the blocks major input and output parameters Each of these parameters will correspond to actual menu settings that you program on the instrument As shown in Figure 8 3 the AM function block s input parameter will be the actual Type J thermocouple run from the furnace to the instrument s All input terminals The AII block will process the thermocouple s millivolt signal to generate a temperature measurement AI1 s output value denoted AI1 OV will essentially be the furnace zone temperature The LP1 function block is shown for now with one input denoted by PV Here the control loop block will expect to find the data comprising its process variable The LP1 block s single output is the loop s main control output Denoted LPI OV Loop 1 s Output Value it will range between 0 and 100 The value of LP1 OV at any given instant will be determined by the control loop function block s PID algorithm The last block in the diagram is the analog output function block AOI Drawn at this point with just a single input and output its primary purpose will be to generate a 4 mA to 20 mA signal that linearly corresponds to whate
308. ode to Configure Function Blocks and Features 9 9 Programming Constants Introduction 5 00 Up to nine constants CN1 through CN9 can be programmed for use by other function blocks as tuning constants slew limits setpoint limits and as the DAT impulse time The output value of a CN block can be a true constant specified during CN programming or a variable value read from another block selected during CN programming The way you make the association between a CN block and the block using its value is unique to CN programming Usually when one function block Block A needs a value from another function block Block B Block A is programmed to read the value of the Block B parameter For example when a loop LP block needs a process variable from an analog input AI block the connection is made during configuration of the LP block In response to the loop s PV prompt you would select PARM then select the AIn OV from the list of available parameters The loop block would read the value from the AI block The CN does provide an OV output value and PV output parameter that are readable by some other blocks During programming of the other block the CN OV would be selected in response to a PARM prompt However there is another way to make the association when Block A needs a value from a CN type Block B but Block A s can only be configured with a number In this case the association is made during configuration of
309. oduction The PCMCIA card memory card must be a DOS formatted SRAM card up to 1 megabyte Formatting may be done in the controller with Online mode STORAGE menu item FMT MCRD see Section 17 DO NOT FORMAT THE CARD WITH A PC USE THE CONTROLLER Maintaining a stock of several formatted cards is recommended to minimize maintenance time on the controller The cards are battery supported memory devices and contain a write protect switch to secure stored data Follow instructions supplied with the PCMCIA cards for battery maintenance ATTENTION Before inserting or removing a card be sure to discharge any static buildup on your body or clothing Table 16 1 shows the procedure for installing and removing memory cards Table 16 1 Memory Card Installation and Removal Procedure easily if you press the bottom of the bezel back towards the panel to compress its gasket 1 Press the button on the underside of the bezel to release the latch The latch will release as you press the button 2 Pull the bottom of the bezel outwards slightly away from the panel and then lift it gently up to fully open it as shown in Figure 16 1 3 Insert the card into the slot until it catches in place 4 To remove the card press the rectangular button next to the slot 5 To close the bezel lower it until it is almost closed Engage the top edge of the bezel first and then swing the bottom inward Press the bottom in firmly un
310. of OFF NUMBER or PARM Press ENTER to make your selection If you want to specify an output value parameter in another function block as the source of a value in the block being edited the follow the procedure in Table 6 2 UDC5300 Controller User Manual 6 13 Modes Menus Prompts and Keypad Basics Table 6 2 Procedure for Selecing a Parameter 1 When a valid response to a prompt is selecting a parameter value from another block the top line of the display will flash PARM To begin to specify a parameter press ENTER The top line of the display will change to show a function block type having a parameter which could be read by the parameter being configured In the case of analog values this is usually Al If this is the type of block you want to specify press ENTER The first block number of this type will be displayed For example the display will change to Alt Use the the the INCREMENT A or DECREMENT VW key to scroll to another block of the same type When the one you want Is on display press ENTER 2b If the first block type displayed is not you choice use the INCREMENT A or DECREMENT VW key to scroll to the desired type For example if you want to read a value from an CN block press W until CN is on display Next do step 2a to select a numbered block instance within the type 3 Once the block ID is displayed on the top line press ENTER The display will change
311. oller The position proportioning output uses the standard CAT output to power the feedback slidewire Current output is changed to voltage out for this purpose Instructions 5 00 The model number breakdown is presented in the tables that follow The basic model number consists of a key number Appended to this key number are characters that identify the features in various categories The meaning of the characters in each category is presented in a table The arrow to the right of the key number marks the selections available One selection is made from each of the tables using the column below the proper arrow A dot denotes unrestricted availability Restrictions follow Table VI UDC5300 Controller User Manual 2 9 Specifications and Model Number Key Number ll lll IV V DC5300 DC530C KEY NUMBER CONTROLLER i i e ee FEE eT standard CE Compliant Note 1 No Preconfiguration Factory Defaults 4 20mA Output Controller Current Heat Cool 4 20 mA and 4 20 mA Specify Table Ill C Heat Cool 4 20 mA and Time Proportioning Relay Heat Cool 4 20 mA and Position Proportioning Specify Table III 3C Ratio Control 4 20mA Outout Specify Table Ill 3 Backup Control 4 20mA output Specify Table III 3D Heat Cool Time Proportioning Relay amp Time Proportioning Relay Heat Cool Time Proportioning Relay amp Position Proportioning Outputs Specify Table Ill 3D Rati
312. om Channel Enter the number of the block within the type of block type to be copied TO CHNL range depends on To Channel Enter the number of the block that is the To Channel type of block destination of the copy operation DO COPY Do Copy Press ENTER to initiate the copy operation The display will ask for confirmation Press ENTER again to complete the operation or press MENU to cancel If the copy is successful the message COPY COMPLETE will be displayed 5 00 UDC5300 Controller User Manual 9 73 Using Program Mode to Configure Function Blocks and Features 9 11 Programming Primary Displays In Online Mode the operator can step through up to ten primary displays by pressing the DISPLAY key Specify which displays are in the sequence and their order using PRG DPYS on the Main Program Menu The online use of these displays is described in Section 14 Not all displays apply to every control strategy For example one primary display shows deviation of the process variable from setpoint and the value of a selected Calculated Value CV for a loop If the loop does not use any Calculated Values this display will not be available Program primary displays prompts Table 9 34 describes the Program Primary Display prompts Table 9 34 Program Primary Display Prompts Prompt Range Selections Definition Full name corresponding to each Display X prompt select the primary display if any to Loop 1
313. on the display e The alarm is entered into the Alarm Summary which shows all active alarm sources e If so configured the alarm is stored in data storage see Section 17 e If so configured the alarm triggers a discrete output relay see Section 9 The relay action returns to normal state only when the alarm state has cleared The alarm will remain active as long as the conditions causing it remain When the conditions no longer exist the alarm will be cleared automatically Clear means that the indicators for the 15 8 UDC5300 Controller User Manual 5 00 Using Online Menu Functions particular alarm on all displays will be removed and the alarm will be removed from the Alarm Summary list An alarm programmed with delay will not activate until its delay time expires An alarm programmed with hysteresis will not clear until its hysteresis time expires Viewing alarm types and setpoints online Instructions for viewing alarm types and setpoints are in Table 15 5 Instructions for changing alarm setpoints online are provided in 15 4 Table 15 5 Procedure for Viewing Alarm Types and Setpoints 5 00 UDC5300 Controller User Manual 15 9 Using Online Menu Functions 15 3 2 Self Diagnostics Introduction The controller runs self diagnostics at powerup and as a background task during operation Diagnostic messages indicate failure of one of these self tests The messages are listed along with possible causes in Section 2
314. ond loop of the controller can be used for furnace temperature control based on the probe temperature input or a separate analog input from a different sensor For boost and diffuse cycles in batch carburizing use the optional setpoint profiler to generate timed setpoints as described in Section 11 A C In order for the output of the control loop LPn to be clamped at Zero until the furnace temperature TPIN equals TPLL the LPn RMAN parameter must be set to CVn OS and LPn OTRK parameter must be programmed with a value of 0 0 not OFF The value 0 0 is not the default for OTRK Description of example The configuration shown in Figure 12 1 uses the C value provided by the OV output of the CARBON type CV block as the PV of a downstream control loop By using a CN constant block programmed with its destination as LP1 HS This loop s setpoint high limit is the anti sooting factor value available as the carbon potential block s auxiliary output A1 Enrichment and dilution of the carburizing gas is accomplished using duration adjusting type DAT output This requires a standard splitter type CV block to activate one relay when the C the loop s PV is above setpoint and a different relay when the PV is below setpoint A control deadband is configurable To permit the display of various values extra CV blocks are used as described below To permit changing values online for the compensation factor representing the CO in the carb
315. onfiguration and calibration see Section 16 e storing data see Section 17 Before attempting to configure a UDC5300 controller for the first time read Section 5 Planning and Section 6 Modes Menus Prompts and Keypad Basics ATTENTION All prompts and selections in this section are listed as displayed when the controller s language is set to English Other languages are available as described in 9 16 What s in this section The following topics are covered in this section Topic Page 9 2 Programming Analog Inputs 9 3 9 3 Programming Loop Blocks 9 12 9 4 Programming Analog Outputs 9 27 9 5 Programming Discrete Inputs 9 35 9 6 Programming Discrete Output Relays 9 37 9 7 Programming Calculated Values 9 38 9 8 Programming Alarms 9 67 5 00 UDC5300 Controller User Manual 9 1 Using Program Mode to Configure Function Blocks and Features Topic Page 9 9 Programming Constants 9 69 9 10 Copying a Block 9 73 9 11 Programming Primary Displays 9 74 9 12 Enabling Features 9 76 9 13 Programming Security 9 78 9 14 Setting the Clock 9 80 9 15 Specifying the Scan Frequency 9 81 9 16 Selecting Display Language 9 82 ATTENTION If you plan to program another function block to use a Calculated Value as the source of a value you must program the Calculated Value first 9 2 UC5300 Controller User Manual 5 00 Using Progra
316. ontroller Each is described in this subsection Will a custom linearization curve be needed for an analog input By default the controller is ready to use a standard input algorithm If your application needs a custom linearization curve enable CUST INP under FEATURES in the Program mode as described in Section 9 Do you need lag and ability to hold input value If your application does not require using a digital filter lag or holding the input under some circumstances simplify the AI programming menus by disabling EXPINP expanded input under the FEATURES prompts described in Section 9 Will the controller monitor for process alarms If alarming is not required at your site or process alarms are monitored by another device disable ALARMS under the FEATURES prompts described in Section 9 Will any values used by the strategy come from a CN constant block If no function blocks will read a value for a CN block simplify the menus by disabling CN constants under the FEATURES prompts described in Section 9 Will operator need to review programming while controller is online If you want to be able to display but not change values of function block parameters while the unit is online enable REVIEW under the FEATURES prompts described in Section 9 5 36 UDC5300 Controller User Manual 5 00 Planning 5 6 Where To Go From Here Modes menus prompts and keypad
317. oop Based on the values of the loop s tuning constants and on how far AMI OV deviates from the 500 F set point the control loop function block s PID algorithm will accordingly adjust LP1 OV to whatever value will be necessary to maintain the process set point LPI OV which ranges from 0 to 100 will in turn be applied to AOI s input to drive the 4 mA to 20 mA control signal applied to the valve actuator By modulating the valve actuator s position this 4 mA to 20 mA signal will regulate the gas flow to the furnace zone burner and thereby allow the instrument to control the heat levels measured in the zone TYPE J THERMOCOUPLE 4 TO 20 mA TYPE STANDARD OUTPUT TYPE CAT SP1 500 INLOW LIMIT 0 GAIN 10 IN HIGH LIMIT 100 RESET 1 OUT LOW LIMIT 4 RATE 0 OUT HIGH LIMIT 20 Figure 8 5 Interconnections Between Function Blocks UDC5300 Controller User Manual 8 5 Learning to Create Custom Programs 6 Draw the Feedback connection 8 6 To fully complete the function block diagram one final and very important interconnection must be drawn In setting up control loops in this instrument a feedback path must be specified between the loop function block itself and the hardware element that externalizes the loop s output to the real world That is the control loop block needs confirmation from the analog output block connected to it that the percent output levels it calls for have been correctly translate
318. or two PP DO blocks and their relays to send control signals to the field Additional information about this use of DO blocks is provided in 5 2 4 3 A DO can also be programmed to read a discrete parameter value from another type of block such as SY1 SF the system block parameter that indicates that the optional data storage memory card is full The output state OS of the DO block is automatically used to open and close the relay associated with each block Refer to the terminal label on the controller This OS can also be read by another block such as a CV block that is programmed to use the DO OS as its input Diagram Discrete Output DO relay C INP OS C input output state UDC5300 Controller User Manual 5 00 Planning 5 2 4 8 Loop Block Use Input Output 5 00 The controller can provide one or two loops of independent or cascade control depending on the model purchased Each loop has an associated LP function block Programming of the internal parameters for the LP block determines the control algorithm used as well as the tuning parameters and other custom values associated with the loop Available control types are e Standard PID for less complex applications e Advanced PID to accommodate feedforward input with gain output tracking setpoint approach compensation soft PID PIDB and remote control actions using logic inputs for more demanding control applications e Split
319. ou tried to load a 2 loop configuration into a 1 loop product Invalid Parameter Bad parameter has been found No user action Code Invalid Parameter for Internal error No user action Data Type Invalid Block Type May appear when trying to make an out of Change type selection range subtype selection For example if choosing analog output type compare type or alarm type message appears if the value of the type is out of range Invalid Tag Request Internal Error No user action Invalid Block Number Internal Error No user action Invalid Machine Update Rate Invalid Channel in Point spec Invalid Input Function block is programmed with wrong Re configure on the product Connection input type Probably caused by someone with Progeny SDA software incorrectly editing the configuration file itself 5 00 UDC5300 Controller User Manual 21 7 Messages Invalid Algorithm Bad algorithm code has been given bad Code algorithm choice Invalid Function Block Request Lag or Delay Less Al lag or delay is less than zero Change lag or delay to than Zero greater than or equal to zero Low Limit Outside of Al circuit low limit is lt voltage limit of 500 mV Change circuit low limit to gt Circuit 500 mV Low Limit Outside of For thermocouple or RTD Range Low limit is Change limit to within Table lt the low limit for that type specified limits for that type see Tabl
320. output value should be displayed You must select a CV whose output is OV that is Peak Picking Signal Select Math Totalizer Interval Timer or Carbon Potential DPYx CN Display x Constant Display x Constant If you select a display containing a constant CN this prompt appears Enter the number 1 to 9 of the CN whose value should be displayed 5 00 UDC5300 Controller User Manual 9 75 Using Program Mode to Configure Function Blocks and Features 9 12 Enabling Features Introduction You can add or remove enable or disable certain prompts to simplify the programming and online menus Disabled functions or data are not destroyed or erased they just cannot be accessed For example a programmed constant retains its value and continues to function in calculations regardless of whether programming of constants is disabled or enabled To enable disable menu items select FEATURES on the Main Program Menu Prompts Table 9 35 describes the Features prompts Table 9 35 Features Prompts Prompt Range Selections Definition Full name Expanded Input DISABL SAMPLE HOLD functions from the Analog Input EXP INP ENABLE Expanded Input DISABL removes the LAG and Programming menu VAL ADJ ENABLE Value Adjust DISABL removes the Analog Input Value Adjust function and the ability to apply value adjust or Value Adjust DISABLE emissivity corrections online FORCE ENABLE Force DISABL removes FORCE fro
321. p 2 STD standard PID 18 In 2 analog Loop 1 STD Loop 1 analog PV 218 Out 1 current standard PID 1 relay Loop 2 analog PV Loop 2 STD standard PID 19 In 3 analog Loop 1 STD Loop 1 analog PV 219 Out 1 current standard PID 1 voltage Loop 2 analog PV 2 relays Loop 2 STD standard PID and analog slidewire feedback from positioner 20 In 2 analog Loop 1 STD Loop 1 analog PV 220 Out 1 current standard PID 2 relays Loop 2 analog PV Loop 2 DIAT PID with Direction Impulse Adjusting Type output 21 In 2 analog Loop 1 CAS_P Loop 1 analog PV 221 Out 1 relay Loop 2 CAS_S Loop 2 analog PV 22 In 2 analog Loop 1 STD Loop 1 analog PV 222 Out 2 relays standard PID Loop 2 analog PV Loop 2 STD standard PID 23 In 3 analog Loop 1 STD Loop 1 analog PV 223 Out 1 voltage standard PID 3 relays Loop 2 analog PV Loop 2 STD standard PID and analog slidewire feedback from positioner 5 00 UDC5300 Controller User Manual 5 27 Planning Table 5 6 Two Loop Factory Configurations continued Loop2 ON OFF Loop 2 analog PV Loop2 ON OFF ON OFF relay Load I O Control Input Output Special Typical Number Hardware Type Signals Signals Features Use Model Needed Selection 24 In 2 analog Loop 1 STD Loop 1 analog PV Loop 1 DAT two independent 224 Out 3 relays standard PID PID loops one with Loop 2 DIAT relay out and one PID with with DIAT relays Directio
322. pecified for the PID algorithm are the limits used in the operating displays of the controller including decimal point location Failure to match the PID range limits with the analog input range limits may cause undesirable operation Control action Specify the desired control action CTLA for the PID algorithm The control action supplied will be REV reverse Direct DIR action is typically used for controlled cooling application Temperature units For temperature control specify an engineering unit for the display F or C for the INEU menu item The controller can display Kelvin or Rankine values but the display only allows for the indication of F or C If K or R is used leave INEU set to NONE Cascade control 5 00 For cascade control configurations enter CAS_P Cascade Primary loop output high and low limits OVHL and OVLL to match the engineering unit span of the secondary loop s process variable The cascade primary control loop is the only loop that provides output scaling Setting these limits to the span of the secondary loop s PV allows the output of the primary loop to be in the proper setpoint units for the secondary controller UDC5300 Controller User Manual 7 5 Using a Factory Configuration 7 3 2 Customization Introduction You can program additional function blocks to add custom features to the strategy For example you may want to add alarm blocks to monitor process values Because any function b
323. pecify Table Ill 3D 2 Loops DIAT Position Proportioning amp DIAT Position Proportioning Specify Table Ill 3D A Features None Setpoint Programming Data Storage interface Setpoint Programming amp Data Storage interface TABLE Ill I O Jone Analog Input Note 3 Three Analog Inputs B Inputs Outputs None 2 Discrete Inputs amp 2 Relay Outputs E Discrete Inputs amp 1 Current Output E Discrete Inputs amp 1 Voltage Output TABLE IV 5 00 UDC5300 Controller User Manual Selection Availability 200 c 216 c 217 b 218 c 219 b 220 c 221 c 222 c 223 a 224 a 225 c 226 a 227 a 228 c oe P S e B BEER eld BEEN e ie 2c ie ee ies w e ee Specifications and Model Number TABLE V OPTIONS English E None 0 JLinen Tag Note 2 L Stainless Steel Tag Note 2 S gt None __ 0 None 0 carbon Potential ae c E Notes 1 Includes one current and two relay outputs 2 Customer must supply Tagging Information Up to 3 lines allowed 22 characters for each line 3 For 4 20 mA inputs a 250 ohm shunt resistor on the input terminals must be used Specify resistor Part 074477 or 311285 for each 4 20 mA input A range of 1 5 volts is used 2 12 UDC5300 Controller User Manual 5 00 Unpacking Preparation and
324. performed using the eight keys on the monoplanar front panel These keys provide push button entry with tactile feedback and are large enough to avoid entry errors even for operators wearing gloves Every parameter in the controller s configuration database and the current value of each can be accessed by cycling through menu displays Access can be password protected or limited to read only More information about the user interface is provided in 1 2 Basics of mode menu and keypad use are provided in Section 6 Operator displays are described in Section 14 Easy to configure Menu driven configuration is fast and easy A control strategy can be loaded at the factory leaving only site specific values such as tuning parameters and range limits to be entered on site These factory configurations are built into the firmware of every UDC5300 so a different strategy can easily be loaded if process requirements change These factory configurations can be modified or a completely new strategy be built from scratch using the complement of function blocks built into every unit A function block is a software object that performs a piece of the control strategy making data available to other blocks Your job is to link these together to define the data flow and to specify their operation by modifying parameter values if the default values are not suitable for your application For example to use an alarm type function block
325. portional except band or of gain Your choice here affects which ON_OFF prompts PB1 and PB2 or GN1 and GN2 are displayed next GAIN Gain is the ratio of output change over measured variable change that caused it PB Percent Proportional Band is the percent of the range of the measured variable for which a proportional only controller will produce a 100 change in its output The relationship between PB and gain can be expressed as GAIN 100 PB For example setting PB 20 will have the same effect on control as setting GAIN 5 Therefore if the change in PV input were 3 of the whole range of possible input values then the resulting change in the output due to proportional only control would be 15 of the output s range regardless of whether GNPB PB and PB 20 or GNPB GN and GAIN 5 Another example Setting PB 50 will have the same effect as setting GAIN 2 In this case if the change in input were again 3 of range then the resulting output change would be 6 GN1 all OFF Gain 1 or PB1 Which prompt is displayed loop depends on the setting entered for GNPB Gain1 types NUMBER Enter the proportional component to be applied by or except range is 0 1 to 200 the control algorithm in the first set of tuning e ON_OFF for Gain parameters OF Enter a starting value at initial configuration The Proportional 0 3 10 1000 0 value may be altered online for final loop tuning If Ba
326. positioning algorithm set to DIAT interfaces between each loop LP block and the discrete output DO blocks associated with the loop s increase and decrease relays In this application the AO 9 66 blocks are not associated with analog output terminals Basic diagram Wiring diagram 7 56 Analog Input 1 V PID Loop1 0 100 i Analog Input 2 V PID 0 100 Loop2 Relay 1 ING DEG Relay 2 DIAT Relay 3 Relay 4 DIAT Actuator Voltage Alt DOS TR ei INC SmE ENGINE DEC WW J S SE EOS aS OQ OF OF Actuator OQ Q Q Q Voltage SECS OQ O HESS Al2 UDC5300 Controller User Manual Using a Factory Configuration Programming diagram l1 TYPE LP1 PV LP1 TYPE AOS INP LINEAR Ali OV DIAT LP1OV DO2 LP1 FB AO3 BC AO3 TYPE PP AO3 PA DIAT AO3 INC DO1 AO3 DEC DO2 C DO3 12 TYPE LP2 PV LP2 TYPE AO4 INP LINEAR Al2 OV DIAT LP2 OV DO4 LP2 FB AO4 BC AO4 TYPE PP AO4 PA DIAT AO4 INC DOS AO4 DEC DO4 5 00 UDC5300 Controller User Manual 7 57 Using a Factory Configuration 7 4 28 Configuration 28 228 Two Independent Loops Eac
327. ppropriate card You can use an unformatted card TEST FACTORY This test is used only at the factory 19 5 Database Services Clearing Configuration and Calibration and Upgrading Optional Features Introduction When DB SRVCE is selected from the Maintenance menu a submenu is accessible It contains the following items CLR CFG Clears only configuration excluding profiles factory default values are assigned to all parameters CALIB Clears only controller calibration ALL Clears all controller memory factory default values are assigned to all parameters FULL UPGRADE If you purchase an upgrade instructions for using this item will be included in the kit INCREMENTAL UPGRADE If you purchase an upgrade instructions for using this item will be included in the kit 19 6 Resetting the Unit Description To restart the instrument to recognize changes to Scan Frequency or Mains Frequency select RST UNIT from the Maintenance menu This function does not clear memory 5 00 UDC5300 Controller User Manual 19 7 Using Maintenance Mode 19 7 Specifying the AC Power Frequency Description To specify either 50 Hz or 60 Hz select MAIN FRQ from the Maintenance menu Afterward you must select RST UNIT to activate this change 19 8 Displaying Firmware Version Information Description When PROD ID is selected from the Maintenance menu the firmware part number and version will be displayed
328. programming a CN constant block s Destination with HS or LS See Programming Constants Section 9 9 Output Decimal Position XX XXKX XXX XXX XXXX XX XXXXX X XXXXXX Output Decimal Position Move the decimal point to the position to be used in the output value provided by the AO block OUTPUT LOW LIMIT OVHL OUTPUT HIGH LIMIT NUMBER Output Low Limit and Output High Limit Enter limits to be used when scaling the output to the input limits e For CAT enter any output range within 0 mA to 20 mA For example a low limit of 4 and high limit of 20 will provide a 4 mA to 20 mA output range e For VAT enter any output range within 0 V to 5 V For example a low limit of 1 and a high limit of 5 will provide a 1 to 5 Vdc output range Output Engineering Units Output Engineering Units Specify the unit of measure Fahrenheit or Celsius for the output this unit is used in the optional data storage database 5 00 UDC5300 Controller User Manual 9 29 Using Program Mode to Configure Function Blocks and Features Table 9 10 CAT and VAT Analog Output Prompts Prompt Applies Range Selections Definition Full name To Limit Limits the rate of increase or decrease of using FSV see below ISLW CAT OFF Increasing Slew Limit and Decreasing Slew VAT bo Slew DAT NUMBER the analog output a r pon i Value entered is in terms of the AO s input patie al i source not in ter
329. prompt and the selection of choices or range of valid values you can enter in response to the prompt After implementing your control strategy with freeform programming read Subsection 9 8 to learn how to configure process alarms If you want to require use of a password to restrict access to the controller s database read Subsection 9 13 to learn how to define passwords and specify what functions require their use Finally read Subsection 9 11 to learn how to specify which displays are available to the operator and their sequence 5 00 UDC5300 Controller User Manual 5 37 Planning 5 38 UDC5300 Controller User Manual 5 00 6 1 Modes Menus Prompts and Keypad Basics 6 Modes Menus Prompts and Keypad Basics Overview This section contains general information about e the controller s operation e the user interface This section is aimed at first time users of the UDC5300 controller Subsequent sections of the manual were written with the assumption that you understand the concepts and terminology presented in this section What s in this section 5 00 The following topics are covered in this section Topic Page 6 2 Modes of Operation 6 2 6 3 User Interface 6 8 6 4 Summary of Key Functions 6 15 6 5 Example 6 18 UDC5300 Controller User Manual 6 1 Modes Menus Prompts and Keypad Basics 6 2 Modes of Operation 6 2 1 Introduction Overview The instrument h
330. r Manual 5 00 Final Preparations for Bringing the Controller Online Table 13 2 Pretune STOP Prompts Prompt Range Selections Definition Full name PT OTSZ 100 to 100 Appears if loop is in Manual Enter the largest change in output or in engineering units that the process Output Size will tolerate The pretune will initiate and analyze this output change PT SPSZ 100 to 100 Appears if loop is in Auto Enter the largest change in setpoint or in engineering units that the process Setpoint Size will tolerate The pretune will initiate and analyze this setpoint change PT STRT Select to start the pretune function See Before Starting Pretune below Before Starting Pretune Before starting Pretune configure adjust the loop as follows Auto Manual Either mode is acceptable Changing the loop mode after starting pretune will abort the pretune causing an error message to appear Process Variable Adjust setpoint or output to bring the process variable to normal operation range Adjusting or switching setpoints or output after starting pretune will abort the pretune causing an error message to appear Gain Proportional Band Reset Use known good settings Alternatively set Gain 1 0 PB 100 Reset 1 0 and place loop in Manual mode Rate Optional If OFF pretune will not calculate a Rate OSUP fuzzy overshoot loop parameter Set to OFF If left on it may cause pretune to abort If desired set OSUP to
331. r Manual 7 31 Using a Factory Configuration 7 4 14 Configuration 14 114 PID with DIAT Relays Out Description This PID loop uses two relays for DIAT direction adjusting impulse type output An analog output AO block with its type set to PP position proportioning and its positioning algorithm set to DIAT interfaces between the loop LP block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO block is not associated with analog output terminals Basic diagram Analog Input 1 0 100 Wiring diagram Alt CIC YIOD O O O O OJo Programming diagram l1 TYPE LP1 PV LINEAR Al1 OV INC Relay 1 PID Loop1 DEC Relay 2 DIAT SIGES S S L1 Actuator S O AA L2 N Voltage S S F DO1 SR INC Sig DEC YS 9 DO2 S LS F DO1 LP1 TYPE AO3 INP DIAT LP1 OV DO2 LP1 FB AO3 BC AO3 TYPE PP AO3 PA DIAT AO3 INC DO1 AO3 DEC DO2 7 32 UDC5300 Controller User Manual 5 00 Using a Factory Configuration 7 4 15 Configuration 15 115 Single Loop with ON OFF Relay Description This loop provides ON OFF control Its PV input is a linear signal received by an analog input AI block A relay served by a discrete output DO function block provides the output Bas
332. r other parameters Function block programming and other activities accomplished in Program mode are described in Section 9 UDC5300 Controller User Manual 6 5 Modes Menus Prompts and Keypad Basics 6 6 PROGRAM gt PROGAI gt Alt gt Al2 gt Al3 gt PROGLP gt LP1 gt LP2 gt PROGAO gt AO1 gt A02 gt AO3 gt A04 gt PROGDI gt DI1 gt DI2 gt DI3 gt PROG DO gt DO1 a DO m gt DO3 gt DO4 gt PROG CV gt CV1 m gt CV2 m gt CV3 gt CV4 r 7 CV16 gt PROGAL gt AL1 gt AL2 gt AL3 m gt AL4 gt PROGCN gt CN1 gt CN2 CN3 gt CN4 wea CN9 gt PROG SPP gt SP1 gt COPY BLK gt BLK TYPE gt FROM CHNL gt TOCHNL gt DO COPY
333. r specified the wrong one you can easily load a different factory configuration using Program Mode This section assumes that you are already familiar with the information in Section 5 Planning and Section 6 Modes Menus Prompts and Keypad Basics Once you have programmed your factory configuration for your application it is good practice to save the configuration to a removable PCMCIA memory card as described in Section 16 1f you controller supports use of a data cartridge What s in this section 5 00 The following topics are covered in this section Topic Page 7 2 Loading a Factory Configuration 7 2 7 3 Tailoring a Factory Configuration to Your Application 7 3 7 4 Detailed Information About Each Strategy 7 7 UDC5300 Controller User Manual 7 1 Using a Factory Configuration 7 2 Loading a Factory Configuration Overview Depending on the hardware on your controller up to twenty eight commonly used factory configurations are available to load into the controller The result of loading a factory configuration is that the function blocks in the controller are programmed to implement the Strategy The factory configurations as specified in Table I of the model selection guide see Section 2 are the same as the factory configurations loaded using the Program menu In the Model Selection Guide the numbers range from 101 through 115 216 through 228 In Program mode the selections range from 01
334. rameter 9 58 OFFL CV ITIMER parameter 9 55 OFFL CV LOGIC parameter 9 46 OFFL CV PTIMER parameter 9 56 OFFL DI parameter 9 35 OFFL DO parameter 9 37 OH1 CV SPLT A parameter 9 62 OH2 CV SPLT A parameter 9 62 OH3 CV SPLT A parameter 9 63 OL1 CV SPLT A parameter 9 62 OL2 CV SPLT A parameter 9 62 ON label choices 9 36 on off control selection 9 14 ONL AL parameter 9 68 ONL CV CMPARE parameter 9 65 ONL CV INV parameter 9 58 ONL CV ITIMER parameter 9 55 ONL CV LOGIC parameter 9 46 ONL CV PTIMER parameter 9 56 ONL DI parameter 9 35 ONL DO parameter 9 37 Online mode outputs state 6 2 submenus 6 4 tasks 1 8 OPER CV CMPARE parameter 9 64 OPER CV LOGIC parameter 9 46 OPER CV MATH parameter 9 44 OPER SECURITY prompt 9 79 OPTZ Pretune STOP prompt 13 2 OSHT 13 3 OSUP LP parameter 9 24 15 6 OTEU AI custom parameter 9 9 OTEU AI standard parameter 9 4 OTEU AO CAT VAT parameter 9 29 OTEU CV ITIMER parameter 9 54 OTEU CV MATH parameter 9 43 OTEU CV PP parameter 9 39 OTEU CV SSEL parameter 9 41 OTEU CV TOTL parameter 9 51 OTEU LP parameter 9 21 OTRK LP parameter 9 24 12 5 14 5 OTSZ Pretune STOP prompt 13 3 OUT AO DAT parameter 9 32 OUT Pretune IDENT and CALC prompt 13 4 output parameters 5 21 OVDB CV SPLT S parameter 9 60 OVHL AO CAT VAT parameter 9 29 OVHL CV ITIMER parameter 9 54 OVHL CV MATH parameter 9 44 OV
335. ration database Extensive diagnostics The controller performs extensive self diagnostics as a background task during normal operation If a problem is detected a message is displayed to alert the operator In addition the operator can initiate keypad and display tests using the Maintenance menu NEMA 12 case With the proper mounting and the front bezel firmly closed the UDC5300 meets the criteria for NEMA 12 Type enclosures for protection from falling dirt and dripping water from the front of the panel See Figure 3 1 for mounting SCF software extends functionality SCF software is available from Honeywell to do all UDC5300 configuration tasks Two features supported by the controller can be configured only using the software entering freeform math expressions for a Math type calculated value CV block and adding custom identifiers for constants CN blocks and calculated values CV blocks These configuration tasks cannot be accomplished using the keypad on the controller s front panel 5 00 UDC5300 Controller User Manual 1 5 Introduction 1 2 Operator Interface Front panel keys used for all setup and operation tasks Eight keys with dedicated functions are on the front panel see Figure 1 2 Use these keys to do all setup operation and maintenance functions Operator displays provide quick access to process values Select the operator displays to be included in the viewing sequence for each loop All include th
336. re Detail Part Description Quantity 22 5 30 047257 Analog Output 3 DI Printed Circuit Assembly 1 22 4 8 Terminal Block 1 22 4 50 Suppression Assembly 1 Kit includes Figure Detail Part Description Quantity 22 5 30 047255 Two DO Two DI Printed Circuit Assembly 1 22 4 8 Terminal Block 1 22 4 50 Suppression Assembly 1 Figure Detail Part Description Quantity 222 54 PCMCIA Card 256 KB capacity 1 1 Kit includes Figure Detail Part Description Quantity 22 5 12 Front Plane Printed Circuit Assembly 1 22 5 26 Display Cable Protector 1 22 4 UDC5300 Controller User Manual 5 00 Parts List Kit includes Figure Detail Part Description Quantity 22 1 46 Panel Mounting Screws 2 22 1 47 Pane Mounting T Bars 2 224 48 NEMA 12 Panel Mounting Gasket 1 Kit includes 225 13 Flat Display Cable 22 4 49 Ground Wire 22 4 24 Ground Bus Bar i 22 4 50 Suppression Assembly i 19 51197863 501 Miscellaneous Hardware Kit Ed Figure Detail Part Description Quantity 224 8 Terminal Blocks 5 222 44 Shell Seal Gasket 1 22 4 43 Cover Plate 5 224 51 Ferrite Clamp 1 22 4 52 INylon Cable Ties 2 22 5 10 Upper amp Lower Rear Supports 1 22 5 11 Reference Junction Sensor
337. relays PID control with out with position proportioning relays PID ratio control out back up to primary controller or PLC uses position proportioning relays out PID control with DIAT relays out single loop with ON OFF relay 5 00 Table 5 6 Two Loop Factory Configurations Planning Output Signals Special Features Typical Use cascade PID with current output PID loops both two independent with current out PID loops one with current out and one with time proportioned relay two independent out PID loops one with current out and one with position proportioning relays two independent out PID loops one with current out and one with DIAT relays two independent out time proportioned cascade PID with relay out PID loops each with time proportioned relay two independent out CAT VAT output provides SPP constant 1 V to power slidewire feedback CAT DIAT DAT DAT DAT VAT output provides PP constant 1 V to power slidewire feedback PID loops one with time proportioned relay out and one with position proportioning relays two independent out Load I O Control Input Number Hardware Type Signals Model Needed Selection 200 16 In 2 analog Loop 1 CAS_P Loop 1 analog PV 216 Out 1 current Loop 2 CAS_S Loop 2 analog PV 17 In 2 analog Loop 1 STD Loop 1 analog PV 217 Out 2 current standard PID Loop 2 analog PV Loo
338. rent Output and One with Position Proportioning Relays Out Description Two independent loops each provide basic PID control For each a linear input served by an analog input AI block supplies the process variable to a standard PID loop The output of one loop is through a CAT current adjusting type analog output AO block The other loop uses two relays to provide a position proportioning output An analog output AO block with both its type and its positioning algorithm set to PP position proportioning interfaces between the loop LP block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO block is not associated with analog output terminals The analog feedback signal from the positioner s slidewire is received at AI2 The feedback is powered by a constant 1 V from the terminals associated with AOI and its VAT voltage adjusting type AO function block having an output range from 0 to 5 Because the input to the AO is 20 from a constant CN block a steady 1 V out is achieved 20 of the 5 V range Basic diagram SEE meat PID Analog Output 2 oy Loop1 0 100 i 4 20 mA INC Analog Input 3 Analog Output 3 Wer Relay 1 PID PV Loop2 0 100 DEC Relay 2 Position Proportioning Analog Input 2 Slidewire Feedback Analog ve SA Output 1 1 V Power for Slidewire Feedback 7 40
339. required to go from Online Mode to Program or Maintenance Mode OPER range is 000 to 999 Operator Security Code Enter the security code to be required to access the operator functions for which security has been enabled using the remaining prompts in this table SET MODE NO Set Mode Specify whether entry of the Master Security Operator Security Code The Operator Security Code must have a non zero value A code of 000 has the same effect as setting the feature s security to NO 9 78 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 36 Security Prompts Prompt Range Selections Definition Full name A M SEL NO Auto Manual Select Set to YES to protect changing Auto Manual VES between a loop s Auto and Manual modes online Select SP1 SP2 NO SP1 SP2 Set to YES to protect changing between a loop s SP1 and SP2 while online YES SET PARM NO Set Parameter Set to YES to protect changes to YES e Tuning Parameters Gain Reset Rate Manual Reset e Pretune e Approach High Low e Output Deadband On Off Control e Bias e Working active Setpoint Slew Limit e Data Entry alarm setpoints constants forcing discretes bias and gain adjustments to analog inputs e Failsafe Value e Analog Input Lag Time e Split Output Deadband e Impulse Time DAT e Minimum On Off Times DAT REVIEW NO Review Set to YES to protect online access to Review VES Programming via
340. rimary Display Description Introduction Figure 14 1 shows an example of a primary display All primary displays follow the same basic format e The PV is shown in the middle of the display e Another value identified by a label such as SP1 is at the bottom of the display in slightly smaller characters In addition indicators above the PV and to the left of the data show e Loop number 1 or 2 Indicates loop for which values are on display e Engineering units F or C or none e manual auto status e MAN lit when the loop is in manual mode e A lit when the loop is in auto mode e A flashing when the loop is in remote manual e A lit with flashing M and N when loop is in init manual the controller puts the cascade primary in init manual if the cascade secondary is put into manual mode by the operator or by the action of a discrete parameter In init manual the output of the primary loop is adjusted to match the setpoint of the secondary so that the transition back to auto mode is bumpless e Active alarm number 1 2 3 or 4 e Setpoint profile status lit when the setpoint profile is executing flashing when the profile execution is being held and off when the profile is at end or ready e Working active setpoint 1 or 2 e The bargraph on the right is a 21 segment deviation bar The middle segment represents 0 deviation of PV from the working active setpoint Each segment above and below the middles
341. rity Introduction You can protect certain menu items and functions from unwanted or accidental access Access to a secured item requires entry of a three digit master or operator code To program security functions select SECURITY to display the Security menu If security is active you will be prompted to enter the master code before continuing Out of the box units do not have security enabled ATTENTION If the master or operator s security code is lost or forgotten a security bypass procedure is available as described in an appendix We recommend that the security bypass appendix be removed from any manual used by operators Security prompts Table 9 36 describes the Security prompts Table 9 36 Security Prompts Prompt Range Selections Definition Full name Enable Security NO security items having a non zero Master or Operator ENABLE YES Enable Security Set to YES to activate security on all Security Code If set to NO no items will be secure M s required to access DB SERV Database Services in T Maintenance Mode and SECURITY in Program Mode If SET MODE is set to YES this code will also be required to go from Online Mode to Program or Maintenance Modes The Master Security Code must have a non zero value A code of 000 has the same effect as setting Enable MASTER range is 000 to 999 Master Security Code Enter the security code to be Security to NO Code should be
342. rmly hooked UDC5300 Controller User Manual 5 00 5 00 Changing the CAT VAT Switch Settings ATTENTION MA mx Pde Latch Lever Figure 20 1 Releasing Latch Levers Location Card Slot 1 _ S1 DIP switch for Analog Output 1 Location Card Slot 3 II 7 i L ooo000000 E E eap E NE S1 DIP switch for Analog Output 2 Figure 20 2 Location Of S1 Switches UDC5300 Controller User Manual 20 5 Changing the CAT VAT Switch Settings 20 6 UDC5300 Controller User Manual 5 00 Messages 21 Messages 21 1 Overview This section provides information about system messages Messages relating to data storage are listed in Section 17 What s in this section The following topics are covered in this section Topic Page 21 2 Diagnostic Messages 21 2 21 3 Loop Error Indicators 21 5 21 4 Error Messages 21 6 5 00 UDC5300 Controller User Manual 21 1 Messages 21 2 Diagnostic Messages Introduction The controller executes diagnostic routines during instrument start up and during maintenance procedures such as calibration It also monitors online operation for both process faults and controller errors Diagnostic messages Ta
343. rogrammed CV 1 through CV 16 Select PRG CV on the Main Program Menu Select a CV to program Select a type The first step in programming a CV block is to specify the CV type Each type has its own set of prompts Available types are listed in Table 9 16 Table 9 16 CV Types Type as Displayed Full Name of Type Prompts Described In NONE cvntused iP PP Peak Picking Function Table917 SSEL Signal Select Function Tableo18 MATH Math Operator Tableo19 O LOGIC Logical Operator Table9 20 TOTL Totalizer Function Table9 23 ITIMER Interval Timer Function Table 9 24 PTIMER Periodic Timer Function Table9 25 INV Inverter Table9 27 SPLT S Standard Split Output Function Table9 28 SPLT A Advanced Split Output Function Table9 29 CMPARE Compare Function Table9 30 CARBON Carbon Potential optional see Section12 ATTENTION The Free Form Math CV lets you create custom equations It is available only on SCF software The configuration must be downloaded to the controller from the computer running SCF software 9 38 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 7 1 CV Peak Picking PP Introduction The peak picking function monitors the input and determines a peak value reached during the specified time interval in minutes The peak can be chosen to be a maximum minimum or
344. rogramming 9 3 9 11 Index Index troubleshooting 13 6 types supported 9 7 9 8 wiring 4 6 4 10 analog output block See AO block analog outputs adjusting online 15 13 and factory configuration 7 4 calibrating for PP 10 7 10 8 programming 9 27 9 34 wiring 4 6 4 13 analog values viewing 15 7 ANLG SUM SUMMARY prompt 15 7 anti sooting factor 12 2 12 11 AO block description 5 9 parameters 9 27 9 34 use with carbon potential CV 12 12 APHI LP parameter 9 20 15 5 APLO LP parameter 9 20 15 5 application examples 8 2 8 14 ASEL CV SSEL parameter 9 42 asterisks on display 13 6 atmosphere generating applications 12 1 AUTO MANUAL See MANUAL AUTO B back calculation values See loops feedback requirements batch data storage 17 4 17 11 BAUDRATE SER COMM prompt 18 2 BIAS LP parameter 9 22 bias adjusting on analog input 15 12 binary protocol 18 2 BLK TYPE COPY BLK prompt 9 73 BT CTRL STORAGE prompt 17 7 17 11 BT NUMBER STORAGE prompt 17 12 BT SETUP SET AED and SET TRND prompt 17 6 17 11 C cabling See wiring CALC Pretune prompt 13 3 calculated value block See CV block calculated values displaying 14 4 programming 9 38 9 66 CALIB AI Maintenance menu item 19 2 CALIB AO Maintenance menu item 19 5 calibrating analog inputs 19 2 19 4 calibrating analog outputs 19 5 19 6 calibration and data storage 17 2 clearing 19 7 storing a
345. rol For each a linear input served by an analog input AI block supplies the process variable to a standard PID loop The output of one loop is through a CAT current adjusting type analog output AO block The other loop uses one relay to provide a time proportioned output A DAT Duration Adjusting Type analog output AO function block interfaces between the loop LP block and the discrete output DO block associated with the time proportioned relay In this application the AO block is not associated with analog output terminals Basic diagram Analog Analog Input 1 SE Output 1 PV Loop 1 0 100 4 20mA Analog Input 2 PV PID Relay 1 i Loop2 0 100 i Time Prop Wiring diagram Al1 AO1 DO1 Zalejelolalole olloa olloa olloa Al2 7 38 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Programming diagram Al1 TYPE LP1 PV Al1 OV LP1 TYPE AO1 INP LP1 OV AO1 TYPE LINEAR STD CAT LP1 FB AO1 BC Al2 TYPE LP2 PV Al2 OV LP2 TYPE AO2 INP LP2 OV DO LINEAR STD AO3 TYPE DAT LP2 FB AO3 BC AO3 OUT DO1 5 00 UDC5300 Controller User Manual 7 39 Using a Factory Configuration 7 4 19 Configuration 19 219 Two Independent PID Loops One with Cur
346. rol algorithm to reduce or eliminate overshoot ATTENTION Regardless of the setting of this parameter overshoot is not suppressed when the process disturbance causes an initial deviation PV SP between 0 7 and 0 7 engineering units Consequently overshoot may not be suppressed in applications which require numerically small loop PV ranges such as carbon potential in which this range is typically 0 0 to 2 0 engineering units OTRK ADV OFF Output Tracking Specify the source of the RATIO value or a constant to be used as the loop s Output CAS S NUMBER output value when Remote Manual is enabled by Tracking DIAT range 0 to 100 the value of RMAN or the value it points to being SPLIT 1 i 55 To have the loop hold its last value when RMAN is 1 set OTRK to LPn OV To use an output value from a CN function block select PARM RMAN ADV OFF Remote Manual Remote Manual Mode is RATIO enabled when the value of RMAN 1 or the Remote CAS S 1 value of the selected discrete parameter 1 Manual DIAT 0 SPLIT When Remote Manual Mode is enabled the loop PARM discrete is taken out of Automatic Mode and the loop output is determined by the output tracking value OTRK In Remote Manual Mode the local DECREMENT and INCREMENT keys are disabled for manual output adjustment In Remote Manual the automatic indicator of the display will flash To override Remote Manual placing the controller in local Manual Mode press the MANU
347. roller User Manual 9 5 Using Program Mode to Configure Function Blocks and Features Prompt Full Name Table 9 2 Standard Al Algorithm Prompts Range Selections Failsafe NONE Failsafe Specify whether or not failsafe is active in case of thermocouple failure burnout and if so which direction An input is considered to have failed when the controller detects loss of continuity or when the input is more than 10 outside the range defined by RGLO and RGHI None Failsafe disabled Up Input will go to full scale value in case of input failure upscale Down Input will go to low value in case of input failure downscale Range Clamp NONE LO RNG HI RNG Range Clamp Specify whether and how out of range input should be clamped ATTENTION Clamping is not recommended for process variable inputs to control loops None Clamping disabled Low Range Input below RGLO value is held at RGLO No clamping on value exceeding RGHI High Range Input above RGHI value is held at RGHI No clamping on value below RGLO Range Input that is out of range in either direction is clamped at value of applicable range limit 9 6 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 3 Analog Input Types Display Symbol Type Operating Span EMF LIN
348. roller Whether the input is normally open or normally closed is configurable as is a delay time If a delay time is specified the DI will wait before indicating that it is ON Input You never have to program the source of a DI block s input because the association between input terminals and a DI block 1s fixed Be sure to observe this correlation A label on the side of the controller identifies the DI number for each set of input screw terminals Output The DI block has a single output OS output state This can be read by other function blocks that can use a discrete value as their input For example a CV block performing a logic operation could point to DI blocks as the source of its inputs Diagram Discrete Input DI iscrete OS input output state 5 00 UDC5300 Controller User Manual 5 13 Planning 5 2 4 7 Discrete Output Block Use Input Output Two output relays are standard on every controller Two more are optional Each discrete output DO block has a fixed association with a relay and its output terminals See terminal label on controller The DO block serves as the interface between other function blocks and the relay When ON OFF control is used the DO is programmed to read its input from the output of the control loop When Duration Adjusting Type DAT or Position Proportioning PP control is used an AO block reads the loop s output then the AO uses one DAT
349. rsion to 1 V to 5 V Shunt resistors are not supplied automatically with the controller and must be ordered separately UDC5300 Controller User Manual 5 00 Wiring Typical Analog Input Connections Terminal board Terminal Input type 9 ues 10 Thermocouple 250 ohm shunt resistor Part no 074477 EMF Up to 5 VDC Figure 4 6 Typical Analog Input Connections Thermocouple inputs Connect thermocouple input leads to the and terminals for analog inputs in card slot 2 Figure 4 3 and Figure 4 6 Use the correct type of extension leadwire for the particular type of thermocouple Thermocouples may be grounded or ungrounded since each point is isolated RTD inputs See Figure 4 6 The A and B leads must be equal in resistance the C lead resistance is not critical ATTENTION In the same controller avoid e Both a thermocouple input tied to ground and an RTD input tied to ground The thermocouple measurement would be incorrect e Athermocouple at a common mode voltage and an RTD tied to ground The common mode voltage would be connected to the ground e Athermocouple at a common mode voltage and an RTD that is ungrounded The common mode voltage would be placed on the RTD 5 00 UDC5300 Controller User Manual 4 11 Wiring Discrete output signal connections Connect discrete output loads to the terminals for discrete outputs in card slot 3 or 4 as shown in Figure 4 7 See Section 2 for output
350. s should be used for communications wiring The recommended cable is Belden 8782 80C The outermost shield must be connected to TB1 Terminal 8 Shield Ground For CE compliance a connection is provided between protective earth We recommend using a conduit for each cable or at least separating them from high voltage lines or magnetic fields Table 4 3 shows the communications wiring procedure Figure 4 11 Table 4 3 Communications Wiring Procedure 1 4 wire Connect the Master s TX signals to each of the RX signals of the Slaves and all the Slave s TX signals to the Master s RX terminals plus to plus and minus to minus 2 wire Connect the instrument s TX to the RX Then connect the instrument s TX to the RX Connect master s A or wire to the TX RX pair on the instrument Connect master s B or wire to the TX RX pair on the instrument 2 Connect unit to unit in a serial or daisy chain fashion with the Master unit at one end and the last unit at the other as shown in Figure 4 11 Set only the last unit s termination ON All other slave units must be unterminated To change a termination setting see Section 18 UDC5300 Controller User Manual 4 15 Wiring 4 Wire Binary andModbus RTU 2 Wire ModbusRTU only PC HOST RX O Master E SHLD ptt e o Ta TR Master x H smo o Slave any address ine Slave any address TX DC pT Slave any address sin Fe EN RX ee Si D T
351. saaischeeseiaans Oana REN 9 56 Table 9 26 CV Periodic Timer Set Up Timer Prompts conesca eaea aeaa a 9 57 500 UDC5300 Controller User Manual o xX Table 267 CN iy Crem Promp S acess este curate REE BSK RDESEE R R SE ERNE ERE SER SE SSE RENEE S 9 58 Table 9228 V Standard Spbtter Prompts veces a hed sister de ao DN dene ed 9 59 Table 929 CV Advanced Splitter Prompts seisine EE 9 61 Fable 9230 CV Compare Pron ES nea E E E 9 64 Table 0 31 ART PrO a E EE 9 67 Fab EO Conine POND e a a aE en eRe Nee Es eT eR arene 9 70 Table 25s A Oy OC Ke OMA Gs Sessa nar an asa a teed etadee he utacenee lites hae eataietaeade 9 73 Table 9 34 Program Primary Display Prompts dic varerne sass a a E E A N 9 74 Table 0555 Peaires PROmpts i nn Re Eee eet eh ER see laste ENES Dkr 9 76 Fable 0 eet Prom BES iss shai i sta a ties ec i ae ica eee oes 9 78 Table 9237 SEEGER PROMS za ala tuenas aan e NE a ku Gala a E ss 9 80 Table 9 38 Scal Frequency SeCleCHONS sii cicsetesics REE SNERRE E E G 9 81 Table 9 59 Lan uae Sele CONS E A ERE 9 82 Table 10 1 Block Configuration to Implement PP Shown in Figure 10 1 00 0 eeeseeeeeeeeeeeeeenaes 10 3 Table 10 2 Procedure for Calibrating the PP OUMU eneninda e E E 10 7 Table Ti l Prosram Setpoint Protmler Promis senri a E en eee lor sis tsar 11 3 TaD eee BR OMe EdE PCO CS catcher a SER SEDEE KDE REE RE ESENSORRE EDER ESEPERE DRED LEESRERE BEREDTE 11 5 Tableti gt Procedure ror stonne ay Pro ule 2
352. sed to select a digit to change The loop must be in local manual mode not in remote manual mode Changing setpoint value This function can be performed on any primary display that shows the setpoint value Pressing the DECREMENT and INCREMENT A keys increases or decreases the setpoint value The LEFT lt 4 key can be used to select a digit to change The following conditions apply 1 Only numerically assigned setpoint values can be changed online If Setpoint 2 is the working setpoint it cannot have been programmed as an analog parameter 2 If the currently active loop is a Ratio Loop only SP1 can be changed Changing a constant s value This function can be performed on any primary display that shows a constant s value Pressing the DECREMENT and INCREMENT A keys increases or decreases the constant s value The LEFT lt 4 key can be used to select a digit to change Changing ratio value Ratio is a gain value applied to an analog parameter which is programmed as the wild input for the ratio control loop The result of the wild variable x Ratio bias calculation is the setpoint for the ratio loop designated as Setpoint 2 SP2 Ratio loops must use only SP2 If the setpoint is changed online to SP1 ratio action will be canceled and the setpoint value will be determined by direct front panel numerical entry You can change the ratio value only on the primary display which shows the process variabl
353. sed when OFF DELA OFF Delay Specify the delay time in seconds When the discrete input goes to its ON state the DI function block Delay NUMBER will wait for the specified delay time before indicating the ON condition as an output If the discrete input goes to OFF before the delay time expires no ON output will be indicated by the function block ONL See Table 9 14 On Label and Off Label Select the labels to be used On Label inthe Summary display and by optional data storage On Label feature when the discrete input is ON value 1 and and OFF value 0 OFFL Off Label 5 00 UDC5300 Controller User Manual 9 35 Using Program Mode to Configure Function Blocks and Features The available selections for ONL and OFFL parameters are listed in Table 9 14 Table 9 14 Selections for ONL and OFFL Parameters Selections NORMAL YES NO 9 36 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 6 Programming Discrete Output Relays Two output relays are standard Two more are optional Each has an associated DO function block The Discrete Output menu item will appear if the optional output relays are installed ATTENTION If a DO block and its relay has been assigned to a DAT or PP function during programming of AO blocks the action state ACST and the input INP of the DO block will not be configurable here see OUT DAT and INC and DEC PP in Se
354. set to program the segment Nn Snn VAL OFF Segment Value Enter the setpoint value for the segment or OFF For a soak enter the previous segment s value S A SARE see Figure 11 1 oo OFF segment Time Enter the amount of time to reach the next Segment Nn Time NUMBER segment value 5 00 UDC5300 Controller User Manual 11 5 Configuring and Using Setpoint Profiler Segment Nn Event1 Snn EV2 Segment Nn Snn EV1 OFF Event2 Snn DV1 OFF Segment Nn ON Deviation Hold1 Snn DV2 OFF Segment Nn ON Deviation Hold2 Configuring the last segment of a profile Table 11 2 Profile Edit Prompts Segment Event 1 and Segment Event 2 Specify whether the SP1 E1 output and SP1 E2 output should be 1 ON or 0 OFF during the segment The transition to the programmed value will occur at the start of the segment and continue to the end of the segment Segment Deviation Hold 1 Specify whether the deviation hold should be enabled ON or ignored OFF during this segment when the value of the parameter specified for DP L1 is compared to the profiler output value SP1 OV see Table 11 1 to program DP L1 Segment Deviation Hold 2 Specify whether the deviation hold should be enabled ON or ignored OFF during this segment when the value of the parameter specified for DP L2 is compared to the profiler output value SP1 OV see Table 11 1 to program DP L2 To properly terminate a profile you must co
355. ssages is displayed when an unusual event has aborted the pretune PTA means Pretune Abort Table 13 5 Pretune Abort Messages Message Meaning User Action Required PTA WARM START A warn start occurred during pretune Repeat pretune PTA WENT OFFLINE Instrument went out of Online mode during pretune Repeat pretune or PV is a constant value such as from an upstream block in manual or Loop has back calculation value from a downstream block that is bad or is the result of the downstream block being in manual PTA LOOP STATUS Loop has PV that is bad i e failed sensor Repeat pretune PTA AM SEL CHNGE Loop switched between automatic and manual modes Repeat pretune PTA SP SEL CHNGE Loop was in automatic mode and an attempt was made to switch between Setpoint 1 and Setpoint 2 Repeat pretune PTA OUT MOVED Loop was in manual mode and loop s output value changed Repeat pretune PTA SP MOVED Loop was in automatic mode and setpoint value changed Repeat pretune PTA LOOP OS Loop is out of service Fix loop before repeating pretune PTA LOOP NOT CFG Loop is not configured Configure loop before repeating pretune PTA BAD STEP SIZ Step size is turned off Set step size to a value before repeating pretune See Table 13 2 PTA ONOFF LOOP Cannot pretune an ON OFF type loop PTA BAD SN RATIO Increase step size See Table 13 2 PTA BAD OSC Repeat pretune with smaller gain or proportional band in loop
356. t 2 4 20 mA Configuration 02 102 Heat Cool with Current Output for Each Analog HEAT Output 1 4 20 mA Analog Input 1 PID CV9 PV Loop 1 Splitter COOL 0 100 C Relay 1 i Time Prop Configuration 03 103 Heat Cool with Current Out for Heat and Time Proportioned Relay for Cool HEAT Analog Output 2 4 20mA Analog Input 1 ae ne 1 i ING Relay 1 0 100 COOL I DEC Relay 2 Position Analog Input 2 Proportioning Slidewire Feedback 0 100 Analog Output 1 1 V Power to Slidewire Feedback Configuration 04 104 Heat Cool with Current Out for Heat and Position Proportioning Relays for Cool Controlled Analog Input 1 a En i PV 0 100 PID bi Loop 1 4 20 mA Wild Analog Input 2 Ratio ariable 0 100 Bias Configuration 05 105 PID Ratio Control with Current Output Figure 5 2 Single Loop Factory Configurations 5 00 UDC5300 Controller User Manual 5 29 Planning Analog a Analog Input 1 PID Output 1 Loop 1 0 100 p 4 20 mA Output Analog Input 3 Tracking Value 0 100 Remote Discrete Input 1 Manual C Relay 1 Status Configuration 06 106 Backup to Primary Controller or PLC Current Output Analog Input 1 eran PID Relay 1 0 100 aie 7 Configuration 07 107 PID wi
357. t Precede Pros anining adelen r S 5 36 5 6 Where Fo Go Prom ere 3 og este cannes e n a 5 37 5 00 UDC5300 Controller User Manual V 6 vi MODES MENUS PROMPTS AND KEYPAD BASICS ccsecccceteeeeeeeeeeneees 6 1 6 1 RON CEN E aoe soak SEE SER A cee Soa oan tec aec eae ate ae ane SENERE ESS REES TET SEE 6 1 6 2 IY Keyes oe y clei gs 010s ommeerenreeceoere N SE anne tne ner SEERE 6 2 SEAN HH Tee e Ue O a B RRESRERERS E a mepeen rune nine es enbnen tr ENDER SE haters netaneen er eneri ere ES ESRENSESRERE S 6 2 Spee aN FE pt OF ECE MOJ ae meres reer DES ere eer rte RT Cree en erp ers ee eres eRe ne eT 6 3 6 3 User INE Eos EBBER REESE RES FIRSERNE PEBER eens deanna ed acne aan oleae vas eee eeaseeaeese 6 8 G5 A ITO GUC MOI a asat cavassasesenasaccaauies cand ESS PE ESEN ES S 6 8 6 522 Usmo the WIENS sissies teat osetia uel ates 6 10 6 4 Summary OF Key Fun Hons orc2ioaiet ete ceciu sides ee aanatete aE eis 6 15 6 5 B 1 010 omer enna etree Sen ome rR ne ence Ney Smear te ENE nee ences REN SES tame SES ENE ERNE Se ene er a 6 18 USING A FACTORY CONFIGURATION cccsccsseeeneeeeeesenseenseeenseeeeesenees 7 1 7 1 I e E T cated eae sete ES O AE E E E EE oleae ge seams gas ae Heer 7 1 T2 Loading a Factory Cono ura UON esii E E E Sadler 7 2 7 3 Tailoring a Factory Configuration to Your Application ccccccceccccccceeesseeeseeeeeeeeeeeeeeaas 7 3 Toul Necessary Cono uratio 2 icasusitatiedan tlre peti N 7 4
358. t profile viewing summaries of system and process data changing setpoints discrete point statuses and analog output tuning values storing data pretuning the loop reviewing programmed entries Program mode tasks Program mode tasks include 1 8 programming all parameters of all function block types except system status block copying blocks selecting the displays for the viewing cycle enabling disabling features such as the use of alarms and constants display of pyrometry input types specifying passwords and selecting the functions to be protected assigning datalink address and other serial communication parameters setting the clock and calendar storing and loading configuration files on removable PCMCIA cards loading a factory configuration setting the scan frequency specifying the language for prompts and menu choices UDC5300 Controller User Manual 5 00 Introduction Maintenance mode tasks 5 00 Maintenance mode tasks include offline functions calibrating analog inputs and outputs running keypad display and memory diagnostics using database services such as clearing the memory clearing calibration and performing upgrades resetting the unit specifying the mains power frequency displaying product ID information including firmware version specifying the length of a power failure that the controller should tolerate without clearing process values interval timer and totalizer values etc UDC53
359. t to be calibrated Go into Maintenance mode and scroll to the CALIB AO prompt Press ENTER Select the input to be calibrated and press ENTER CALIB Aon LOW will be displayed The display will show ENTER WHEN SET Use the INCREMENT A and DECREMENT VW keys to adjust the output The meter will read approximately 4 mA CAT or 1 V VAT Press ENTER until the meter reads the correct low value Press ENTER to store the calibration Scroll down to CALIB Aon HIGH and follow the same procedure The meter should read 20 mA CAT or 5 V VAT When calibration of the output is complete power down the controller before disconnecting the test leads Move the meter to another output if desired and repeat the procedure Restore the field wiring to the calibrated output with all power removed UDC5300 Controller User Manual 5 00 Using Maintenance Mode 19 4 Running Diagnostics Introduction Select RUN DIAG to test any of these areas TEST DISPLAY Select this to test all display characters Any failed display items should be apparent TEST KEYPAD Select this to verify operation of each key When each key is pressed its name should be displayed except MENU which terminates the keypad test TEST RAM SIZE Shows amount of RAM If less than 384KB replace the CPU TEST MEM CARD Select this to verify read write PCMCIA card function This test destroys all card data so use an a
360. ta type trend alarms events diagnostics Filenames and extensions are as follows Trend Data FILEO LNT Alarms FILEO1 LNA Events FILEO1 LNE Diagnostics FILEO1 LND Starting and stopping storage 17 10 All applicable discretes and menus must be enabled for storage to be active If any are disabled no storage will occur The following items enable disable storage 1 STORAGE Storage Use to ENABLE or DISABL data storage This command must be set to ENABLE to allow data storage as a background task Once enabled changing the setting to DISABL will stop storage of data Storage and loading of Setpoint profiles and configuration will function with storage disabled UDC5300 Controller User Manual 5 00 Storing Data 2 EXT ENAB External Enable Any discrete parameter specified here will control data storage in either continuous or batch modes A high logic 1 enables storage and a low logic Q disables storage This item is found under DS SETUP 3 BT CTRL Batch Control or BT SETUP Batch Setup BT CTRL appears only if BATCH mode is selected If BT SETUP is set to NONE you must select BT CTRL items START and STOP to control batch data storage START starts storage and increments the batch number STOP is the default upon initialization and stops batch storage If BT SETUP is defined with a discrete BT CTRL displays read only the status of that discrete START or STOP and the discrete parameter specified wil
361. talled memory card UDC5300 Controller User Manual 17 13 Storing Data 17 14 UDC5300 Controller User Manual 5 00 Setting Up for Serial Communications 18 Setting Up for Serial Communications 18 1 Introduction Overview Serial communications capability is an optional feature that enables the controller to exchange data with a host device a PC running Honeywell or other compatible software on an RS422 485 data link Using a proprietary Honeywell protocol or Modbus RTU this link can be used to transfer configurations and data To see if your controller is capable of performing serial communications compare the model number on the instrument tag with the model selection guide in Section 2 If the controller will use serial communications the unit must be programmed as described in this section In addition the last instrument in the data link must be terminated This is also described in this section Wiring the controller to the data link is discussed in Section 4 What s in this section The following topics are covered in this section 5 00 UDC5300 Controller User Manual 18 1 Setting Up for Serial Communications 18 2 Programming Serial Communications Introduction To program communications select SER COMM from the main Program Menu Serial Communication prompts Table 18 1 lists the Serial Communications prompts Table 18 1 Serial Communications Prompts Unit Address Enter the un
362. ter type CV block in the data flow between your loop block and the output blocks can send the output to one actuator when the PV is above setpoint and a different actuator when PV is below setpoint Several factory configurations take advantage of this splitter to provide reliable control of both heating and cooling equipment by a single loop Nine CN constant blocks can each provide a true constant or a variable read from another block for use as an input from anther block Use this block type to provide dynamic values to ratio setpoints or tuning parameters Four AL alarm blocks can monitor process variables see below These block types are supplemented by the SP Setpoint profiler block used to configure the values times and event statuses associated with each ramp or soak segment of the profile see below A special SY system block monitors the status of the controller s operations and makes these statuses as well as the reference junction temperature available as outputs readable by other blocks Alarms Up to four process alarms can be configured If the alarm state becomes active an indicator lights on the display to alert the operator The alarm is entered in an Alarm Summary that lists all active alarms As an option it can also be logged by the data storage function If current signal is used instead of voltage use a shunt resistor as described in Section 4 5 00 UDC5300 Controller User Manual 1 3
363. ter See standard splitter CV and advanced splitter CV SPLL LP parameter 9 21 SPSE LP parameter 9 25 SPSZ Pretune STOP prompt 13 3 SPT1 LP parameter 9 20 15 5 SPT2 LP parameter 9 21 15 5 SPTR LP parameter 9 20 SQRT AI custom parameter 9 10 SSEC CV PTIMER setup parameter 9 57 standard PID control selection 9 14 standard splitter CV 9 59 9 60 12 12 START setpoint profiler STATUS prompt 11 11 starting controller 13 6 STATUS accessed with SETPOINT PRGM key 11 10 STATUS DS STATS prompt 17 11 17 12 STATUS Pretune COMP prompt 13 4 STATUS Pretune IDENT and CALC prompt 13 4 STATUS Pretune STOP prompt 13 2 STOP Pretune prompt 13 2 STORAGE Online menu item 17 3 STORAGE SECURITY prompt 9 79 storing configuration setpoint profile etc See name of item to be stored STPn accessed with SETPOINT PRGM key 11 10 STPT AL parameter 9 68 STRG MOD SET AED prompt 17 6 STRG MOD SET TRND prompt 17 4 STRT Pretune STOP prompt 13 3 SU CAP DS STATS prompt 17 11 17 12 SUMMARY Online menu item 15 7 Super Systems Inc 12 3 12 4 T temperature units and factory configuration 7 5 terminating datalink 18 3 18 5 thermocouple inputs specifications 2 4 types supported 2 8 wiring 4 11 three step output See DIAT output time setting 9 80 viewing 15 7 TIME Pretune IDENT and CALC prompt 13 4 TIME SUMMARY prompt 15 7 Index time proportioned output See DAT output tim
364. teristics Using Program Mode to Configure Function Blocks and Features Table 9 5 lists loop characteristics and issues to think about when configuring your controller Eight loop types available Control with position proportioning devices with and without feedback capabilities Minimum programming requirements 5 00 Table 9 5 Loop Characteristics is the default type However this may be changed see IACT prompt described in Table 9 8 If you want to change the algorithm change it Two PID algorithm types interacting and noninteracting Noninteracting before starting loop configuration previously programmed entries for the LP block will be set back to the If the loop type is changed after LP configuration is completed all defaults You will be prompted to save your entries when leaving the loop program sequence Configuration checks are executed at this time to verify all entries are complete and compatible A FAIL message at this time may indicate incomplete entries or incompatible selections When programming Split Output control loops tuning parameter set 1 is automatically applied to output values between 0 and 100 Tuning parameter set 2 is automatically applied to output values between 0 and 100 True position proportioning PP output is available This requires the use of an analog input from a slidewire feedback and is available with standard PID Advanced PID ratio and cascade secondary loop typ
365. th Time Proportioned Relay Output HEAT Relay 1 Time Prop Analog Input 1 PID CV9 PV i p Loop 1 Splitter COOL Time Prop PV Time Prop Configuration 08 108 Heat Cool with Time Proportioned Relay for Each HEAT Relay 1 Time Prop Analog Input 1 py pee a INC Relay 3 0 100 CBR prer COOL P a DEC Relay 4 Position Analog NpuLA Proportioning Analog Output 1 1 V Power to Slidewire Feedback Slidewire Feed back 0 100 Configuration 09 109 Heat Cool with Time Proportioned Relay for Heat and Position Proportioning Relays for Cool Controlled Analog Input 1 PV 0 100 Relay 1 Time Prop Analog Input 2 Ratio 0 100 pias Wild ariable Configuration 10 110 PID Ratio Control with Time Proportioned Relay Out Figure 5 2 Single Loop Factory Configurations continued 5 30 UDC5300 Controller User Manual 5 00 5 00 PV Slidewire Feedback Analog Input 1 STE PID Loop 1 0 100 Analog Input 2 0 100 Planning INC Relay 1 DEG Relay 2 Position Proportioning pg 1 1V Configuration 11 111 PID with Position Proportioning Relays Out Analog Input 1 INC Controlled Relay 1 PID 0 100 Loop 1 LDEC Relay 2 Analog Input 3 Wild
366. the CN Block B For example suppose you want the loop block to use a constant from the CN block as the loop s bias When configuring the loop you would enter a number in response to the BIAS prompt Then when configuring the CN block you would specify the loop s bias parameter as the destination of the CN block value At runtime the CN block will write the value to the loop block overwriting the configured number More information about configuring destinations 1s provided in Destination Programming Issues below To configure a CN block select PRG CN on the Main Program Menu Select a constant to program ATTENTION Constants are configurable only if CN is set to ENABLE under FEATURES in the Programming Menu as described in 9 12 UDC5300 Controller User Manual 9 69 Using Program Mode to Configure Function Blocks and Features Constant prompts Table 9 32 describes the Constant prompts Input Decimal Position INHL Input High Limit Input Engineering Units 9 70 Input Low Limit Table 9 32 Constant Prompts OFF Input Specify the source of the input to the CN block or enter a number If a number is entered here the operator eee can change the value online using the Data Entry menu PARM analog XX XXXX Input Decimal Position Move the decimal point to the XXX XXX position used by the input to the alarm function block XXXX XX XXXXX X XXXXXX OFF Input Low
367. the CV calculated value block can be set up to do any one of twelve different operations such as serving as a periodic timer performing a comparison making a calculation or splitting an output Table 5 2 lists the block types their functions and the quantity of each type available Table 5 2 Function Block Types Function block Code Function Quantity name Alarm AL Monitors for process alarm conditions 4 Analog Input Al Interfaces with measuring input hardware 3 Analog Output AO Interfaces with analog output hardware CAT VAT or with 4 discrete output blocks DAT PP Calculated Value CV Performs various calculations on specified analog or discrete 16 values Constant CN Outputs a constant or a value from another blocks analog 9 parameter Discrete Input DI Interfaces between discrete input hardware and other blocks 3 Discrete Output DO Interfaces between other blocks and output relay hardware 4 Loop LP Executes selected control algorithm 1 or 2 Setpoint Profiler SP Outputs a time varying setpoint used by a loop s SP2 1 diagnostics outputs analog value of reference junction temperature This function block is not programmable its outputs are produced automatically Maximum configurable quantity depends on I O hardware options in the model Models DC530_ __ _ P and DC530_ ___ B only Number of loops depends on model s
368. the control algorithm to reduce or eliminate overshoot ATTENTION Regardless of the setting of this parameter overshoot is not suppressed when the process disturbance causes an initial deviation PV SP between 0 7 and 0 7 engineering units Consequently overshoot may not be suppressed in applications which require numerically small loop PV ranges such as carbon potential in which this range is typically 0 0 to 2 0 engineering units 15 6 UDC5300 Controller User Manual 5 00 Using Online Menu Functions 15 3 Viewing Displays in the Summary Group Introduction 5 00 The SUMMARY item in the Online menu provides access to a wealth of information about the controller as it interacts with the process Table 15 3 describes the Summary prompts Table 15 3 Summary Prompts Prompt Definition Full name ALRM SUM See 14 3 1 Alarm Summary DIAG SUM See 14 3 2 Diagnostic Summary Analog Summary These include all analog I O loops calculated values ANLG SUM Displays current value of all analog values in the controller totalizers and system parameters Discrete Summary These include all discrete I O alarms loops totalizers and DISC SUM Displays current status of all discrete values in the controller system parameters DEL DIAG See 14 3 2 Delete Diagnostic TIME Displays current time and date If these are incorrect they can be reset in Program mode using SET CLK PROD ID Displays part
369. the current adjusting type signal available at the controller s output terminals INP AL 1 STPT 500 sP1 1500 Figure 5 1 Sample Function Block Connections The output value of AI is also used as the input to an alarm block AL1 If the process value falls below the alarm setpoint 500 the alarm block changes the value of its discrete output OS to 1 AL1 OS is in turn the input to a discrete output block DO1 DO1 is associated with a relay When the input to DOI becomes 1 the relay goes to its alarm state and the annunciator wired to the relay alerts the operator to the alarm condition Alarms are also indicated on the controller display Table 5 1 summarizes this configuration Not all parameters are shown 5 00 UDC5300 Controller User Manual 5 3 Planning Table 5 1 Programming Required to Accomplish Connections in Figure 5 1 Function Input Programmed Internal Programmed Block Parameter With Output Parameter s Parameter i Al 1 P 4 TYPE 3 J p E IEEE se Se LP 1 PV Alt OV SP1 1500 AT Nei AMOV s a oo DO 1 INP ALIOS e 5 4 UDC5300 Controller User Manual 5 00 Planning 5 2 3 Function Block Complement Overview The function block types available are designed to enable you to configure the controller to satisfy the requirements of a wide range of applications Additional versatility has been designed into each function block type For example
370. the probe type PROB furnace correction factor FURN and three inputs e amy signal from a zirconia oxygen probe the value is read by input PBIN e the probe temperature the value is read by input TPIN e the percent carbon monoxide CO present in the gas used for carburizing the value is provided by parameter CO It can be a fixed value or read from an analog input Produce a value output A2 which represents the dewpoint of the furnace atmosphere based on the probe type PROB percent hydrogen HYDR and two inputs e amy signal from a zirconia oxygen probe the value is read by input PBIN e the probe temperature the value is read by input TPIN Produce an anti sooting value output Al based on probe temperature from TPIN this value can be used as a setpoint high limit for a downstream control block see 12 4 Provide a discrete parameter output OS which is HIGH 1 when the probe temperature is below a customer configured limit TPLL and LOW 0 when the probe temperature is above that limit This discrete can be used in conjunction with other parameters to clamp the output of a downstream control loop at zero until the TPLL temperature is reached Probes supported 12 2 The probes supported include Advanced Atmosphere Control Corp Furnace Control Corp Marathon Monitors Super Systems Inc The CARBON type CV block has a PROB
371. the storage schedule of a unit in service If the clock time is reset more than 5 minutes back the following actions will take place 1 Data in storage buffers will be copied to the memory card and the buffers will then be cleared 2 Data collection for storage will stop until the operator reinitializes the schedule If the clock is set back less than 5 minutes collection of the data for data storage feature will stop until the setback time elapses and the clock catches up with the original collection schedule see Section 17 for more information about data storage 9 80 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features 9 15 Specifying the Scan Frequency Introduction The scan frequency also known as scan rate scan cycle update rate is configurable This is the time used to read inputs execute function blocks and update outputs To specify the frequency select SCAN FRQ from the main Program Menu Scan Frequency selections Table 9 38 lists the Scan Frequency selections available when the SCAN FRQ prompt is on display Table 9 38 Scan Frequency Selections Selections 1 SEC second 500 MS milliseconds 250 MS milliseconds 125 MS milliseconds only for model with single analog input 5 00 UDC5300 Controller User Manual 9 81 Using Program Mode to Configure Function Blocks and Features 9 16 Selecting Display Language Introduction The
372. this is true then CVn OS is PULSE Used for interfacing with slower Result switches ON 1 for lt ON 1 for CONDITION circuits CONDITION TIME then TIME then OFF O On rising edge of Result OFF 0 During CONDITION creates pulse length TIME any additional CONDITION TIME and ignores OFF 0 to ON changes of additional rising edges of Result Result are ignored within that CONDITION TIME Condition Type Pulse Condition Time 3 seconds If Result is Then CVn OS is CONDITION TIME Result switches ON 1 for gt ON 1 for CONDITION CONDITION TIME then TIME then OFF 0 RT PULSE Used for slower circuits Result switches ON 1 for lt ON 1 for CONDITION Re triggerable pulse CONDITION TIME then TIME then OFF 0 OFF 0 Guarantees that CVn OS will be Result switches ON 1 ON 1 when Result first ON for CONDITION TIME after multiple times before switches ON 1 and most recent rising edge of CONDITION TIME expires remains ON 1 until Result Result has not switched ON 1 for Condition Time 3 seconds lf Result is 4 sec se is Then CVn OS is re trigge Condition Type Re triggerable Pulse 5 00 UDC5300 Controller User Manual 9 49 Using Program Mode to Configure Function Blocks and Features Table 9 22 CV Logical Operator Definitions
373. til the latch clicks into place Be careful to fully close the bezel or the unit will not function normally 16 2 UDC5300 Controller User Manual 5 00 Storing and Loading Configuration and Calibration Figure 16 1 Inserting A Memory Card 5 00 UDC5300 Controller User Manual 16 3 Storing and Loading Configuration and Calibration 16 3 Storing and Loading Configuration and Calibration Introduction Loading and storing configuration and calibration data are done in Program mode Select CFG FILE from the Program menu 16 3 1 Storing to Card Procedure 16 4 The procedure for storing configuration and or calibration to a memory card is in Table 16 2 Table 16 2 Procedure for Storing Configuration and or Calibration Step Action 1 Insert a PCMCIA card into the controller The display will show STORE CFG gt MOD To take this action storing the configuration press ENTER The display will change to STORE PROFILO1 3 To select a different name and number press the DECREMENT VW key The display will change to STORE CONFIG01 2 Go to CFG FILE in the Program mode menu and press ENTER 4 Press the W key to scroll through the name choices When the name string you want is displayed press ENTER The controller is now ready for you to change the number 01 if desired 5 To change the number press the W key to scroll through the number from
374. time proportioned relay for cool 04 In 2 analog SPLIT analog PV CAT for heat CV block splits heat cool with 104 Out 1 current PID with split output current out for heat 1 voltage output and and MARE and outpu iti 2 relays analog slidewire PP for cool A run os ET position p proportioning relays w p for cool positioner slidewire feedback 05 In 2 analog RATIO analog controlled CAT PID ratio control 105 Out 1 current PID for ratio variable with current out and analog wild variable 06 In 2 analog ADV analog PV CAT relay out used for back up to primary 106 1 discrete advanced PID Remote Manual controller or PLC Out 1 current and status uses current out 1 relay analog source of Remote Manual output value and discrete input for Remote Manual status 07 In 1 analog STD analog PV DAT PID control with 107 Out 1 relay standard PID time proportioned out 08 In 1 analog SPLIT analog PV DAT for heat uses CV block to heat cool with time 108 Out 2 relays PID with split split output proportioned relay output and for each xx Number in Table I of Model Number Breakdown see Section 2 5 00 UDC5300 Controller User Manual 5 25 Planning Model Selection 09 109 5 26 I O Hardware Needed In 2 analog Out 1 voltage 3 relays In 2 analog Out 1 relay In 2 analog Out 1 voltage 2 relays In 3 analog Out 1 voltage 2 relays In 3 analog 1 discrete Out 1 voltage 4 relays
375. tion 20 provides details Procedure 10 2 Table 10 1 indicates the key parameters to be programmed to implement the PP strategy illustrated in Figure 10 1 Your application may require the configuration of additional parameters unrelated to PP in these function blocks Be sure to review the available parameters in Section 9 or step through all the parameters for each block programmed to be sure you do not miss anything applicable Remember if factory configuration 11 or one of the other factory configurations providing PP output suits your needs load it Much of the programming described in Table 10 1 will be done for you automatically We list the configuration steps in detail in that table to demonstrate the principles of PP configuration UDC5300 Controller User Manual 5 00 Position Proportioning Output Setup and Calibration Table 10 1 Block Configuration to Implement PP Shown in Figure 10 1 1 Program the block being used for PV to match the sensor input type and range for the controlled variable In our example Ali TYPE LINEAR Ali RNGL 0 0 Ali RNHI 100 0 2 Al2 must be used for the slidewire feedback Program the block with Al2 TYPE LINEAR Al2 RNGL 0 0 Al2 RNHI 100 0 Al2 D ID INDIRE Al2 CKLO 0 00 Al2 CKHI 1 00 Al2 CKUN VOLTS Al2 LAG 0 0 3 Select a loop type from the available selections STD ADV SPLIT RATIO CAS Por DIAT Configure the loop s input to be read from the Al bl
376. tion block having an output range from 0 to 5 Because the input to the AO is 20 from a constant CN block a steady 1 V out is achieved 20 of the 5 V range Basic diagram Analog Input 1 Controlled Analog Input 3 Wild SER 0 100 Variable Slidewire Ratio Bias Analog Input 2 INC Relay 1 PID Loop1 DEC Relay 2 Position Proportioning Analog Feedback Wiring diagram 0 100 Alt bg 1 1V Controlled eae ES V G CD i Sane ag ASE L1 Actuator H S ES O LAN Voltage OS RSS ERS a ahs Ol O CO I INC CS TAS EG VES SEG ire ECE WES STS TS OH eea INC Al3 Al2 Wild DEC 7 28 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Programming diagram Alt TYPE LP1 PV C DO1 LINEAR Al1 OV LP1 TYPE AO INP RATIO LP1 OV ROL AI3 TYPE LP1 WILD i LP1 FB LINEAR AI3 OV AO3 BC AO3 TYPE PP AO3 PA PP AO3 INC DO1 AO3 DEC DO2 Al2 TYPE AO3 SLWR Al2 OV LINEAR CN9 IN AO1 INP 20 CN9 OV AO1 TYPE VAT AO1 INLL 0 AO1 INHL 100 AO1 OVLL 0 AO1 OVHL 5 5 00 UDC5300 Controller User Manual 7 29 Using a Factory Configuration
377. to by the CV block Probe Type Specify the type of oxygen probe supplying the input Advanced Atmosphere Control Corp Furnace Control Corp Marathon Monitors Co Super Systems Inc Probe Input Specify the source of the oxygen probe input to the CV block Temperature Input Specify the source of the oxygen probe s temperature input to the CV block Fahrenheit Celsius Kelvin or Rankine in which the Temperature Units Specify the unit of measure temperature input value at TPIN is supplied UDC5300 Controller User Manual 5 00 Carbon Potential Option Table 12 3 CV Carbon Potential Prompts Prompt Range Selections Definition Full name TPLL OFF Temperature Low Limit When TPIN lt TPLL then Temperature Low NUMBER OS 1 When TPIN TPLL then OS 0 Limit This limit can be used along with a loop force manual input to ensure that the output of a control loop is clamped at zero until the furnace temperature is at the desired level WARNING In order for the output of the control loop to be clamped at zero until the temperature of TPIN equals TPLL you must also program the following 1 Configure LPn RMAN CVn OS and 2 Configure LPn OTRK 0 0 not OFF THE VALUE 0 0 IS NOT THE DEFAULT FOR OTRK CO source of the value of the percent carbon monoxide CO present in the gas used for carburizing This value is required by the algorithm that computes output OV the C present i
378. to show the block ID and the code for one of its output parameters that is a valid choice To see other outputs from the same block that can be used as the source of the value of the parameter being configured use the INCREMENT A and DECREMENT V keys 4 If you change your mind and want to select a different type of block use the MENU key to move back up through the hierarchy then use the A and V keys to select another type 5 When the desired block ID and output code are on display press ENTER to select it The cursor will move back down to the prompt You are ready to use the W key to go on to the next prompt 6 14 UDC5300 Controller User Manual 5 00 Modes Menus Prompts and Keypad Basics 6 4 Summary of Key Functions In all modes the instrument is operated by using the front panel keys to view and select items from menus and displays Table 6 3 describes each panel key and its functions Table 6 3 Key Functions Operating mode in which function applies Acknowledges diagnostic and other messages Accesses Online mode MENU from online primary display Backs cursor out of a menu to next higher menu level Use when finished looking at or changing menu items When at the top level of a menu goes to first item on menu If prompted to SAVE CHANGES press to exit menu without saving changes INCREMENT Moves cursor up a menu or list of choices When entering the most significant digit of a number
379. to this key and changes instrument to online mode e Each press accesses the next display in the sequence 6 16 UDC5300 Controller User Manual 5 00 Modes Menus Prompts and Keypad Basics Table 6 3 Key Functions continued Symbol Name Function Operating mode in which function applies MANUAL MANUAL e Ina loop display toggles loop v AUTO AUTO between Auto and Manual modes loop s Remote Manual RMAN discrete must be OFF e Ina loop display toggles loop v between Remote Manual and Manual modes loop s Remote Manual RMAN discrete must be ON e Does not function if loop s Discrete v vs Key discrete is ON In this case the key s functioning has been transferred to the loop s Auto Manual Select A MS discrete in the loop block SETPOINT SETPOINT e Accesses displays used to view v PRGM PRGM setpoint profile status e Enables A and W for setpoint v profile operation functions 5 00 UDC5300 Controller User Manual 6 17 Modes Menus Prompts and Keypad Basics 6 5 Example Introduction Table 6 4 presents an example of the key sequences needed to select an item from a list of choices In this case we will specify that AI2 is a T thermocouple Table 6 4 Example Procedure for Selecting an Item Upon powering up the controller for the first time a logo will be displayed Press MENU until a prompt is displayed If itis PRG Al you are already in Program mode and can skip to Step 4
380. tory configuration using Program Mode as described in Section 7 Proceed with programming site specific values for internal parameters and the job is done If none of the factory configurations exactly matches your requirements load the one that is the closest match Customize it by adding and or subtracting function blocks until the configuration is precisely what you need 5 00 UDC5300 Controller User Manual 5 23 Planning 5 4 Factory Configuration Applications Introduction 5 24 This subsection is intended to provide the big picture on each of the available factory configurations so you can decide which one meets your needs To see basic diagrams of each factory configuration see Figure 5 2 and Figure 5 3 To see a listing of the basic features such as control type and output type see Table 5 5 and Table 5 6 Before loading one of these strategies go to Section 7 Additional information is provided there about each strategy including a more detailed diagram identifying the function blocks used and a wiring diagram That section also advises you which parameters require your custom values before the controller goes online When considering the available strategies remember that not every controller model has the I O hardware to support every configuration The tables and figures use the abbreviations shown in Table 5 4 Table 5 4 Abbreviations Used in This Section Abbreviation Meaning CAS
381. troller User Manual 5 00 Configuring and Using Setpoint Profiler Changing profiler s status When STATUS is displayed pressing the INCREMENT A and DECREMENT VW keys will sequence through the operating menu of the Profiler The selections are shown in Table 11 6 Table 11 6 Setpoint Profiler Status Menu Prompt Definition Full name Starts a profile from the Ready RDY or Held HLD states SPP indicator ON HOLD Holds the profile holds time remaining in the segment to its current value SPP indicator FLASHING ADVNCE When the profile is held or ready select this to advance the profile to the next segment in sequence After ADVANCE START will start the profile at the beginning of the selected segment status Profiles may not be Reset from the Active state No SPP indicator RESET Resets a HLD or ENDed profile to the RDY ready Changing a segment time or value While a setpoint profile is in the active or held state the segment values and segment time may be altered in any segment Table 11 7 Changing a Segment Time Or Value 1 Select SP PRFLR from the Online menu The value of the current segment after the active one will be displayed 5 00 UDC5300 Controller User Manual 11 11 Configuring and Using Setpoint Profiler Holding a Profile An active profile may be held by five methods When online and in hold the SPP indicator flashes The five hold methods are 1 By t
382. type Other significant parameters are the input source a CN the input range and the output range Turn all other selections to OFF or NONE Leave the decimal positions at the defaults In our example AO1 TYPE VAT AO1 INP CN9 OV AO1 INLL 0 0 AO1 INHL 100 0 AO1 OVLL 0 00 AO1 OVHL 5 00 5 Program the AO block that will interface between the loop and the DO blocks for the relays This must be a PP type Its input must be the output of the control loop The selection for the positioning algorithm can be PP any control algorithm or AUTO DIAT control type only The source of the slidewire feedback must also be specified as well as the discrete outputs associated with the increase and decrease relays In our example AO3 TYPE PP AOS INT LP1 OV AOS SLWR Al2 OV AO3 PA PP AO3 INC DO1 AO3 DEC DO2 Make the initial setting for the drive unit sensitivity DUSE at 99 8 This may be adjusted later if necessary to prevent motor oscillation and position overshoot Maximum sensitivity is 100 Set the drive unit soeed DUSP to match the full scale travel time of the actuator Example If the actuator takes 40 seconds to travel from 0 to 100 position use 40 0 as the DUSP value Any DO blocks and their relays used for the PP output cannot be used for another purpose such as alarm annunciation Therefore once a DO block has been selected for an INC or DEC parameter here the DO block s
383. ual the output is set by the operator using the controller s keypad To use the MANUAL AUTO key three conditions must be met 1 The loop must be in local mode which means the value of the loop s remote manual control RMAN parameter must be zero 2 The loop s Discrete vs Key DIKY discrete must have a value of zero 3 If security is active for manual auto changes the security code must be entered first For a description of the loop parameters RMAN and DIKY see Section 9 Using remote manual mode 5 00 When the loop is in remote manual its RMAN parameter has a value of one This forces the controller s output to be the Output Tracking OTRK value Usually the source of the OTRK value is an analog input block receiving the value from a primary controller or PLC Remote manual mode can only become active when the loop is in auto Remote manual is indicated by the A for auto indicator flashing In remote manual the DECREMENT VW INCREMENT A and LEFT lt 4 keys are disabled Pressing MANUAL AUTO while in remote manual switches the controller back to local manual mode UDC5300 Controller User Manual 14 5 Using Primary Displays to View Process Values and Change Setpoints Changing loop output This function can be performed on any primary display where output is shown Pressing the DECREMENT and INCREMENT A keys will lower or raise the loop output displayed as The LEFT lt 4 key can be u
384. ulse adjusting output through two relays An analog output AO block with its type set to PP position proportioning and its positioning algorithm set to DIAT interfaces between the Loop 2 LP2 block and the discrete output DO blocks associated with the increase and decrease relays In this application the AO block is not associated with analog output terminals Basic diagram y Analog Input 1 PID Analog Output 1 Loop1 0 100 a 4 20 mA INC Analog Input 2 Relay 1 y PID Loop2 0 100 DEC Relay 2 DIAT Wiring diagram All Gii Ve OQ OF CO Or l Sass WOR K R L1 Acua A GO EO OS ATAN Voltage OQ On OC soi OQ On Ol INC SE CSTR SO a A E TF S F TRE LS ENS Al2 7 42 UDC5300 Controller User Manual 5 00 Using a Factory Configuration Programming diagram 5 00 Al1 TYPE LINEAR Al2 TYPE LINEAR LP1 PV Al1 OV LP1 TYPE AO2 INP LP1 OV AO1 TYPE STD CAT LP1 FB AO2 BC LP2PV LP2 TYPE AO3 INP Al3 OV DIAT LP2 OV ROL LP2 FB AO3 BC AO3 TYPE PP AO3 PA DIAT AO3 INC DO1 AO3 DEC DO2 UDC5300 Controller User Manual 7 43 Using a Factory Configuration 7 4 21 Configuration 21 221 Cascade PID with T
385. ult NMICSSAGCS sx sacd ikun he nale se nende stoker bedre anne ede bats oueaahaadiaedatbadmertunele 21 4 Table 21 3 Abnormal Loop Conditions and Indicators cccccssessesseeeeeecceeeeeeeeaeseeeesseseeeeeeeeeeeeaeaas 21 5 Fable iA ETONE S 8 CS S RENS BEES RES SE SED RSEFSSESSES OE 21 6 500 UDC5300 Controller User Manual SO mi Figures Foure Tail WDC 5300 Front Panek eerie E tates EA se nase i ende E A 1 1 Fisure 1 2 Display Indicators and Key FUNCHONS 2 roser eneret Verne stenet leves E A 1 7 Fieu cy t MOUNN Samemeeneenen ee pier nce tune en veneer ne ree tueee A stairs tr peers rt 3 4 Figure 4 1 Noise Suppression For Output ccc cccsccccsseccessseceesseeceseecessseccesseeceeseeeeseeeeeses 4 5 Figure 4 2 Slot 1 Terminal Connections 0 0 0 0 cceecssssecsssecsessessssecsseseeseecssseeseeecsssseseaeecssnsessaneess 4 6 Figure 4 3 Sloe2 Termina Connections aug enkel tale e a ded etic ennen 4 7 Pigre A Slot 3 Terminal Connec HoA S esesmrinn a ders hirse Netto she eler at Soares A 4 8 Figure 4 5 Slot4 Termina Connections sisis e E ER 4 9 Figure 4 6 Typical Analog Input Connections ccccccccccccccassssseeeeseeeececceeeeeeceeaaaaaessseeeeeeeeeeeeeeeeeaaaas 4 11 Fiowre 4 7 Discrete VO CORRE ELO Sas anna al tetrad aint E eN ue arrede Aar 4 12 Proure 4 8 PP Typical Wirio criss tons Aiton n i a ene dende bade eaaa 4 13 PIGure 409 DIAT Typical Wirid zsiros aa aS 4 14 Figure TO DAT Typical Wiring esenee e a aa 4 14 Figure 4 11 Networ
386. unciation the output status OS of an AL block can be used as the input to a discrete output block The discrete output s relay can turn on an external annunciator when an alarm state occurs The alarm s input PV and the compare point value of a deviation alarm S2 are also available as AL outputs Special information If alarming is not necessary at your site or if alarming is being handled by another device you can simplify the menus by turning off all references to alarms See 9 12 After alarms have been programmed access to setpoints can be removed from menus by turning off all references to alarms The programmed alarms will continue to operate Diagram Alarm PV Same as input value INP input S2 compare pt value STPT alarm setpt CMPT OS compare pt of output dev alarm status 5 6 UDC5300 Controller User Manual 5 00 Planning 5 2 4 2 Analog Input Block Use Use the analog input AI function block type to serve as an interface between the field device and the controller One AI block is associated with each hardware analog input The AI block converts the field signal to a form usable by the control loop Standard input algorithms are available to handle input from a variety of commonly used devices Input types that the AI can handle include EMF linear many common thermocouples and Rayotube and Spectray pyrometers For special applications a custom input linearization curve can
387. une a loop follow the procedure in Table 15 1 Table 15 2 describes the Loop Tuning parameters Table 15 1 How To Toggle and or Tune A Loop 2 Scroll to Loop1 or Loop 2 and press ENTER The selected loop will be displayed on the bottom line of the display along with the prompt SPT Above it will be the option TOGGLE Note that the appropriate setpoint indicator 1 or 2 will be lit 3 To toggle to the other setpoint press ENTER The setpoint indicator will change to the other number 4 If you do not want to change the value of any tuning parameters at this time press MENU to exit loop tuning for the selected loop If you do want to change the value of a tuning parameter then instead of pressing MENU press the DECREMENT W key Use it to scroll through the tuning parameters for the selected loop 5 Select any of the parameters in to be tuned Parameters available depend on the loop type being tuned Tuning parameters are described in Table 15 2 UDC5300 Controller User Manual 15 3 Using Online Menu Functions Table 15 2 Loop Tuning Parameters To allow integral only control select OFF Note that use of the second set of tuning parameters is enabled with DTUN a loop prompt available in Program mode RST1 RST2 OFF Reset in Repeats per Minute 1 and 2 Specify how Prompt Range Selections Definition Full name GN1 GN2 OFF Gain 1 and Gain 2 or PB1 and PB2 Which prompt is displaye
388. ures Figure 9 1 Math CV Feedback Programming 5 00 UDC5300 Controller User Manual 9 45 Using Program Mode to Configure Function Blocks and Features 9 7 4 CV Logic LOGIC Introduction The logic CV function block performs logic operation on the values from up to eight inputs using a single operator The result is available as CVn OS The output CVn OS 1 if the logic is true CV logic prompts Table 9 20 describes the Logic prompts Table 9 20 CV Logic Prompts Prompt Range Selections Definition Full name OPER AND See Table 9 22 CV Logical Operator Definitions Logical Operator OR XOR PASS RS FF TGL FF 1 SHOT INP1 OFF Input Source 1 through Input Source 8 Use these prompts to specify the source of the inputs to the CV apne l function block through 0 INP8 PARM discrete Input 8 ONL SeeTable9 14 On Label and Off Label Select the labels to be used in the Summary display and by optional data storage On Label feature when the output is ON value 1 and OFF and value 0 OFFL Off Label Condition Type DELAY erase for interaction between condition types and EXTEND PULSE RT PLS 9 46 UC5300 Controller User Manual 5 00 Using Program Mode to Configure Function Blocks and Features Table 9 20 CV Logic Prompts Prompt Range Selections Definition Full name CTIM OFF Condition Time Specify the condition time See Gondiion Time NUMBER a for intera
389. urizing gas CO parameter and the furnace factor FURN CN constant blocks are used 12 6 UDC5300 Controller User Manual 5 00 O Probe Output Alt i O Probe Temp Y CV1 MATH Al1 OV 0 Display 3 CO CONSTANT 2 Display 6 Furnace Factor CONSTANT 1 gt Display 7 5 00 Carbon Potential Option Display 4 Enrichment S1 Setpoint AO3 PBIN C OV cv2 CARBON O R FB POTENTIAL Anti Sooting SEN C V CONTROL Factor SPLIT E CONSTANT 3 _ SP CONTROL Mae OSA TPIN Al gt LP1 HS HIGH LP1 INP a na l LIMIT CV3 A2 FB2 gt RMAN A HOW OTRK OS Temperature m r Discrete Number 0 0 CO A2 Zowpant MATH CV4 Display 5 Dilution CV2 A2 0 DP FURN Figure 12 1 Diagram of Carbon Potential Configuration Example UDC5300 Controller User Manual 12 7 Carbon Potential Option 12 4 2 Function Block Configuration Millivolt input from oxygen probe The mV signal from the zirconia oxygen probe is processed by an AI function block In our example the field wiring goes to the AI input terminals Table 12 4 shows the programming for the AII block in Figure 12 1 Table 12 4 Al1 Configuration for Oxygen Probe Input Al1 Programming
390. ut block Feedback inputs must have a span equal to the loop output span when they are not pointed Feedback Specify the source of the loop s directly to analog output blocks NUMBER PARM analog to the PID equation as an addition It is included in the bumpless transfer calculations The value of FFIN should not exceed 0 to 100 units Feedforward is typically used to provide an output change in anticipation of a change to the Feed Forward Input The FFIN value is applied loop process variable Prompt Applies Full name To MOFF ON_OFF Manual Off FB all I Feedback E except ON_OFF FFIN ADV RATIO Feed Forward CAS P Input CAS S DIAT SPLIT FFGN ADV RATIO Feed Forward CAS P DIAT SPLIT NUMBER range is 10 00 to 10 00 Feed Forward Gain Specified value is applied as gain to the feed forward input value 5 00 UDC5300 Controller User Manual 9 23 Using Program Mode to Configure Function Blocks and Features Table 9 8 Loop Prompt Descriptions Prompt Applies Range Selections Definition Full name To OSUP STD NO Fuzzy Overshoot Suppression When YES is ADV selected suppression is enabled limiting the Fuzzy CAS P YES overshoot of the setpoint by the process variable Overshoot DIAT after a disturbance in the process such as a load Suppression SPLIT change or setpoint change Through fuzzy logic the working setpoint of the control loop is dynamically modified by the cont
391. ut block See DI block discrete inputs programming 9 35 9 36 wiring 4 13 discrete outputs programming 9 37 wiring 4 12 discrete statuses viewing 15 7 display indicators 1 7 14 2 DISPLAY key functions 6 16 DL LKOUT SER COMM prompt 18 2 DO block description 5 14 parameters 9 37 DO COPY COPY BLK prompt 9 73 DPL1 SP block parameter 11 3 Index 2 UDC5300 Controller User Manual 5 00 DPL2 SP block parameter 11 3 DPYx CN PRG DPYS prompts 9 75 DPYx CV PRG DPYS prompts 9 75 DS FILES STORAGE prompt 17 12 DS INIT STORAGE prompt 17 3 17 10 DS SETUP STORAGE prompt 17 4 DS STATS Online menu item 17 11 DSEL CV SSEL parameter 9 42 DSLW AO CAT VAT parameter 9 30 DSLW AO DAT parameter 9 31 DSLW LP parameter 9 21 15 5 D TM AL parameter 9 68 DTUN 9 25 duplex control See split output duration adjusting type output See DAT output DUSE AO PP parameter 9 33 DUSE SET AO prompt 15 13 DUSP AO PP parameter 9 33 DVPHL PROFILE prompt 11 5 DVPLL PROFILE prompt 11 5 E editing parameter values 6 12 6 14 EMIS AI custom parameter 9 9 emissivity adjustments 15 12 ENAB CV TOTL parameter 9 53 ENABLE SECURITY prompt 9 78 ENTER key functions 6 16 error messages 13 5 17 13 21 1 21 9 ETIME accessed with SETPOINT PRGM key 11 10 EVENT DS STATS prompt 17 11 17 12 event outputs 11 2 11 6 11 10 EVENTS accessed with SETPOINT PRGM
392. utput will be applied to a function called a standard splitter STD SPLITTER Made from one of the instrument s calculated value function blocks CV s the standard splitter will essentially be a mechanism that translates the values of the split output control loop into two distinct 0 to 100 signals They will be applied to the inputs of AO1 and AO2 and as such will drive and linearly correspond with AOI and AO2 s 4 mA to 20 mA outputs 4 TO 20 mA INPUT TYPE PT100 47020 mA TYPE SPLIT 100 100 CV1 A2 CV1 A1 100 100 LP1 OV Figure 8 10 Function Block Diagram of Figure 8 9 The two outputs on CV 1 that will drive AOI and AO2 are respectively labeled CV1 A1 and CV1 A2 CV1 s basic operation is described by a plot of these outputs versus LP1 OV Shown in the lower left of Figure 8 10 the plot demonstrates that CV1 will produce a 0 to 100 value at its CV1 Al output when LPI calls for an output level between 0 and 100 CV1 A2 will remain at 0 When applied to AOI the CV1 A1 value will activate the 4 mA to 20 mA signal needed at the hot water valve actuator to make the water temperature in the vessel rise Similarly when LP1 calls for an output level between 0 and 100 CV1 will produce a corresponding 0 to 100 value at CV1 A2 This time CV1 A1 will remain at 0 and the CV1 A2 value generated will induce the introduction of cold water into the vessel to cool its conte
393. utside world the DOT output relay represented by the DO1 function block will be programmed for AO1 s exclusive use Hence as AOI switches between ON and OFF states in response to LP OV s output levels so too will the DO output relay to generate the pulses required to drive the caustic reagent pump 8 8 UDC5300 Controller User Manual 5 00 Learning to Create Custom Programs 8 4 Split Output or Duplex Control Introduction 5 00 Split output or duplex control loops are typically used in heat cool applications Temperature is controlled through simultaneous use of both heating and cooling elements If the instrument was to support a heat cool control configuration an example of the control scheme that might be dealt with is illustrated in Figure 8 9 CONTROLLER PV 85 SP 95 OUT 73 5 VALVE 4 TO 20 mA ACTUATOR CAT HOT WATER HOT WATER 4 TO 20 mA CAT PLATINUM RTD COLD WATER COLD WATER VALVE WATER TANK Figure 8 9 Temperature Control of Water Using Split Output or Duplex Control The instrument must be set up to produce two 4 mA to 20 mA control signals By applying them to current controlled valve actuators coupled to hot and cold water valves these signals will regulate the amount of hot and cold water introduced to the vessel to maintain the water temperature at whatever set point will be programmed The temperature of the water will be measured by means of a three wire 100 Q Platinum RTD T
394. ver value is applied at its input For example if AO1 s input is defined as some value that ranges from 0 to 100 an input value of 0 will cause AO to generate a 4 mA signal at the instrument s AOI output terminals A 12 mA signal will be generated in response to an input of 50 while 20 mA will result when a 100 input value is applied AOTI s input parameter is denoted IN with its output parameter labeled to identify it as the physical 4 mA to 20 mA signal detectable at the pair of instrument rear terminals dedicated to AOI UDC5300 Controller User Manual 8 3 Learning to Create Custom Programs TYPE J ab THERMOCOUPLE 4TO20mA Figure 8 3 Labeling Each Function Block s Name and Major Inputs and Outputs 4 Label function block parameters Finally label each block s internal parameters Internal parameters may also be referred to as function block parameters As in the case of input and output parameters internal parameters associated with each block correspond to actual menu settings you program in the instrument While input and output parameters constitute either data exchanged between function blocks or physical signals exchanged between the instrument and the outside world internal parameters are settings that uniquely define the operation of the function block they are associated with Use of a function block s internal parameters is for the most part limited to within the operations of the
395. you specify that its input will be the value from an analog input You specify its operation such as high alarm low alarm or deviation alarm by selecting its action from a list then you enter the setpoint If you want a relay to activate when the block detects an alarm state point to the alarm block s output with the DO discrete output function block associated with the relay Function block basics are provided in 1 4 Section 5 contains more information about factory configurations and function blocks so you can plan how to use the controller to implement your strategy Section 7 provides detailed information about each factory configuration Inputs and outputs 1 2 The standard inputs and outputs provided in the controller include one universal analog input one current or voltage output can be switched on site 1 form C relay and 1 form A relay to support a wide range of loop configurations Two additional analog inputs are available You can also have your choice of two discrete inputs and two more relays or three discrete inputs with another current or voltage out The controller has dozens of built in analog input algorithms to handle signals from a wide variety of thermocouple RTD or pyrometry sources as well as any linear input Alternatively you can enter a custom conversion curve by defining up to twenty points Each hardware input and output has an associated function block to serve as an interface between the
396. ype of calibration 25 mV 75 mV etc 17 2 UDC5300 Controller User Manual 5 00 Storing Data Setting Up Data Storage Data Storage setup is done Online to avoid interruption of current storage All setup selections are found in the Online mode menu item STORAGE See Table 17 2 ATTENTION Before inserting or removing a card be sure to discharge any static buildup on your body or clothing Table 17 2 Data Storage Setup Procedure Insert a formatted memory card in the card slot If necessary format card using FMT MCRD in the Storage menu Instructions for inserting a card are provided in Section 16 Set STORAGE to ENABLE No storage can occur if this is disabled regardless of other settings 3 Select DS SETUP to specify storage mode and other settings See DS SETUP in this section If you choose BATCH storage mode the discrete parameter that will control start and stop of data storage must be defined See BT SETUP in this section 4 Select DS WARN to enter 0 99 When trend alarm or diagnostic storage reaches this Capacity the operator will be warned 5 Select DS INIT INITTYPE NEW to initialize the memory card with the settings from steps 3 and 4 Initialization activates storage and allots a file for each data type trend alarms events diagnostics The filename extensions identify the file contents FILENAME EXT Contents FILEO1 LNT Trend FILEO1 LNA Alarms FILEO1 LNE Events FILEO1 LND Diagnostics
397. ys is described in Section 14 What s in this section The following topics are covered in this section p Topic Page 15 2 Tuning a Loop and or Toggling the Setpoint 153 15 3 Viewing Displays in the Summary Group 15 7 15 4 Data Entry 15 11 15 5 Reviewing Programming 15 14 5 00 UDC5300 Controller User Manual 15 1 Using Online Menu Functions ATTENTION All prompts and selections in this section are listed as shown when the controller s language is set to English The controller can be configured to display prompts and messages in other languages as described in Section 9 ATTENTION The controller can be programmed to require the entry of a password before changing tuning parameters changing alarm setpoints and other activities described in this section If you are locked out of any function described here see your process engineer 15 2 UDC5300 Controller User Manual 5 00 Using Online Menu Functions 15 2 Tuning a Loop and or Toggling the Setpoint Introduction The value of loop tuning parameters can be changed online to adjust the operation of a loop to best respond to the requirements of the process In addition the Online menu TUNE LP item is used to toggle between Setpoint 1 and Setpoint 2 for the selected loop Some primary displays can also be used to toggle between setpoints see Section 14 for details Loop tuning procedure 5 00 To toggle the setpoint and or t
398. zes a value such as a flow rate over time The output CVn OV is a running total When this total reaches or exceeds the preset limit value PSET the totalizer resets to zero the discrete output CVn OS turns on goes to 1 for one cycle and the totalizing restarts Using PRG DPYS you can specify that the output value of the CV used as a totalizer be included in a primary operator display CV totalizer prompts Table 9 23 describes the Totalizer prompts Table 9 23 CV Totalizer Prompts Engineering Units 5 00 Prompt Range Selections Definition Full name IDPT XX XXXX Input Decimal Position Move the decimal point to XXX XXX the position used by the inputs to the CV block Input Decimal XXXX XX Position XXXXX X XXXXXX ODPT XX XXXX Output Decimal Position Move the decimal point to XXX XXX the position to be used in the output value provided by Output Decimal XXXX XX the CV block Position XXXXX X XXXXXX INP OFF Input Source Specify the source of the input to the Input NUMBER CV function block PARM analog OTEU OFF Output Engineering Units Specify the unit of measure Fahrenheit or Celsius for the output Output F UDC5300 Controller User Manual 9 51 Using Program Mode to Configure Function Blocks and Features Table 9 23 CV Totalizer Prompts Prompt Range Selections Definition Full name preset value PSET is assumed to be in the same ACTION units as OTEU UP Up Ea

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