Honeywell UDC3500 Installation and operating instructions

Controller Failure Symptoms

Introduction

In addition to the error message prompts, there are failure symptoms that can be

identified by noting how the controller displays and indicators are reacting.

Symptoms

Compare your symptoms with those shown in Table-1.

Table-1 Controller Failure Symptoms

Upper

Display Lower

Display Indicators Controller

Output Probable

Cause Trouble-

shooting

Procedure

Blank Blank Off None Power Failure 0

OK OK

Current

Proportional

Output

OK OK

Position

Proportional or

TPSC Output

OK OK

Time Proportional

Output 0

Displayed

Output

disagrees

with Controller

Output

Controller

Output

disagrees

with Displayed

Output

Current/Time

Proportional

Output

OK OK OK

External Alarm

function does

not operate

properly

Malfunction in

alarm output 0

OK Displayed

Output

disagrees with

First Current

Output

OK Controller

Current Output

#1 disagrees

with Displayed

First Current

Output

First Current

Output 0

OK Displayed

Output

disagrees with

Second Current

Output

OK Controller

Current Output

#2 disagrees

with Displayed

Second Current

Output

Second Current

Output 0

OK Displayed

Output

disagrees with

Third Current

Output

OK Controller

Output

disagrees with

Displayed Third

Current Output

Third Current

Output 0

Page 1 of 16 Revision 1

Upper

Display Lower

Display Indicators Controller

Output Probable

Cause Trouble-

shooting

Procedure

Display does not change when a key is pressed Keyboard

Malfunction 0

Controller fails to go into “Slave” operation during communications Communications

Failure RS-485: 0

Ethernet: 0

Bad PV Reading Bad InX

Reading OK OK

Analog Input

Failure 0

Other symptoms

If a set of symptoms or prompts other than the one you started with appears while

troubleshooting, re-evaluate the symptoms. This may lead to a different troubleshooting

procedure.

If the symptom still persists, refer to the installation section in this manual to ensure

proper installation and proper use of the controller in your system.

Troubleshooting Procedures

Introduction

The troubleshooting procedures are listed as they appear in Table-1. Each procedure

describes what to do if you have that particular failure and how to do it or where to find

the data needed to accomplish the task.

WARNING—SHOCK HAZARD

TROUBLESHOOTING MAY REQUIRE ACCESS TO HAZARDOUS LIVE

CIRCUITS AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE

PERSONNEL. MORE THAN ONE SWITCH MAY BE REQUIRED TO DE-

ENERGIZE UNIT BEFORE SERVICING.

Equipment needed

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

• Multimeter – Capable of measuring millivolts, volts, milliamps and resistance.

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

Page 2 of 16 Revision 1

Procedure #1 – Power

Table 2 explains how to troubleshoot power failure symptoms.

Table 2 Troubleshooting Power Failure Symptoms

Step What to do How to do it

1 Check the AC or DC line

voltage. Use a voltmeter to measure the AC or DC

voltage across terminals L1 and L2 on the rear

terminal panel of the controller.

Check the earth ground connection.

2 Make sure the chassis plugs

into the rear of the case

properly.

Withdraw the chassis and visually inspect the

controller board and the inside of the case.

Reseat the boards into the Chassis if

necessary.

3 Check the system for Brown-

outs, heavy load switching, etc.,

and conformance to installation

instructions.

Refer to Installation Section.

4 Change Power board. Installation instructions supplied with new

board.

Procedure #2 – Current Outputs

Table 3 explains how to troubleshoot Current Output failure symptoms.

Table 3 Troubleshooting Current Output Failure

Step What to do How to do it

1 Make sure that the controller is

configured correctly and that the

proper range (4 to 20 or 0 to 20)

is configured.

Refer to Configuration Section.

Configuration incorrect: Fix configuration

Configuration correct: Go to Step 2.

2 Check the field wiring. Output impedance must be less than or equal

to 1000 ohms.

3a First Current Output: Test for

operation. Change Output Set Up group function prompt

OUT ALG = CUR.

Make the Output Set up group function prompt

CO RANGE = 4–20

Go to Step 4

3b Second Current Output: Test for

operation. Change Options Set Up group function prompt

CUR2 OUT = OUTPUT

Make the Current #2 Options Set up group

function prompt CO RANGE = 4–20

Go to Step 4

Page 3 of 16 Revision 1

Step What to do How to do it

3c Third Current Output: Test for

operation. Change Options Set Up group function prompt

CUR3 OUT = OUTPUT

Make the Current #3 Options Set up group

function prompt CO RANGE = 4–20

Go to Step 4

4 Check the output. Put the controller into Manual mode and

change the output via the front keyboard from

0 % to 100 %. Use a DC milliammeter at the

rear terminals for the output being diagnosed

to verify the output.

Output works correctly: Return the controller

to its original configuration and check output

again.

Output does not work correctly: Go to Step 5.

5 Restore Factory Calibration For the output being diagnosed, change the

CO RANGE prompt from its present setting to

its other setting. Exit the setup group and then

return and change CO RANGE back to its

previous setting.

Output works correctly: Finished

Output does not work correctly: Go to Step 6.

6 Field Calibrate the output. Refer to Output Calibration Section for details.

Output works correctly: Finished

Output does not work correctly: Go to Step 7.

7 Change Current Output board. Installation instructions provided with new

board.

Page 4 of 16 Revision 1

Procedure #3 – Position Proportional

Table 4explains how to troubleshoot Position Proportional Output failure symptoms.

Table 4 Troubleshooting Position Proportional Output Failure

Step What to do How to do it

1 Make certain that the controller

is configured properly for

Position Proportional output.

Make Output Algorithm Set Up group function

prompt OUT ALG = POSPROP.

Make Input 3 Set Up group function prompt

IN3 TYPE = SLIDEW

Refer to Configuration Section.

If the “CAL MTR” diagnostic prompt is flashing

on the lower display, then this means that the

instrument was never calibrated for your

application. See the Position Proportional field

calibration procedure in Output Calibration

Section for motor slidewire calibration

procedure.

2 Check the field wiring. Refer to Installation Section for details.

3 Check whether the motor

drives in both directions. Put the controller into Manual mode. Vary the

output above and below the present value.

Observe “OUT” indicators and the output value

(“OUT”) on the lower display. When the “OUT

1” indicator is on and the “OUT 2” indicator is

off, then the motor should be opening and the

output value shown on the lower display

should be increasing. When the “OUT 1”

indicator is off and the “OUT 2” indicator is on,

then the motor should be closing and the

output value on the lower display should be

decreasing. Listen for a click from a relay

when the OUT1 and OUT 2 indicators change

state.

a) Motor moves in both directions but the

displayed Output value does not change or

does not have a decimal point – Go to Step 4

b) Motor does not move in one or both

directions – Go to Step 5

c) Motor moves in both directions but the

displayed Output value moves in the wrong

direction: This means that the motor or the

slidewire or both are incorrectly wired. Check

the motor manufacturer’s wiring diagram and

then refer to Installation Section to rewire the

controller.

Page 5 of 16 Revision 1

Step What to do How to do it

4 Motor moves in both directions

but the displayed Output value

does not change or does not

have a decimal point

Slidewire input is malfunctioning. See the

Position Proportional field calibration

procedure in Output Calibration Section for

motor slidewire calibration procedure. Follow

that procedure to Field Calibrate the

instrument. If after a Field Calibration the

problem is still not fixed, then go to Step 6.

5 Motor does not move in one or

both directions Wiring Problem. Check the motor

manufacturer’s wiring diagram and then refer

to Installation Section –to rewire the controller.

If wiring is correct, then go to Step 7.

6 Determine if Motor Slidewire or

Input 3 is at fault. Disconnect and tag the field wiring for the

slidewire. Refer to Installation Section .

Measure the voltage between the R (28) and

the – (30) terminals.

Voltage is +1.2Vdc ±0.2Vdc: Bad motor

slidewire. Refer to the motor manufacturer’s

instructions.

Voltage not +1.2Vdc ±0.2Vdc: Check the

Jumper on the Input 3 Board . Jumper should

be in W1 position. If not, then move it to W1

position and recalibrate the instrument per

Output Calibration Section. If the Jumper is in

the W1 position, then replace the Input 3

board. Installation instructions supplied with

the new board.

Page 6 of 16 Revision 1

Step What to do How to do it

7 Check the Relays. Turn off power to the motor and to the

instrument. Disconnect and tag the field wiring

to the relays. Relay 1 (MOTOR – OPEN) is on

terminals 8 and 9. Relay 2 (MOTOR – CLOSE)

is on terminals 7 and 8.

Turn on power to the instrument. Put the

controller into Manual mode. Connect your

multimeter to terminals 8 and 9 and set the

multimeter to measure resistance. Now, vary

the output above and below the present value

and observe the “OUT” indicators and your

multimeter. When the “OUT 1” indicator is on,

then Relay 1 should be closed and there

should be only a few ohms between terminals

8 and 9. When the “OUT 1” indicator is off,

then Relay 1 should be open and there should

be infinite resistance between terminals 8 and

9. Listen for a click from the relay when the

OUT1 indicator changes state.

Repeat this test for Relay 2 by connecting your

multimeter to terminals 7 and 8. When the

“OUT 2” indicator is on, the relay should be

closed and there should be only a few ohms

between terminals 7 and 8. When the “OUT 2”

indicator is off, the relay should be open and

there should be infinite resistance between

terminals 7 and 8. Listen for a click from the

relay when the “OUT 2” indicator changes

state.

Relays measure correctly: Check motor. Refer

to manufacturer’s instructions.

Relays do not measure correctly: Go to Step 8.

8 Replace the Dual Relay Board. Installation instructions supplied with the new

board.

Page 7 of 16 Revision 1

Procedure #4 – Time Proportional

Table -5 explains how to troubleshoot Time Proportional Output failure.

Table -5 Troubleshooting Time Proportional Output Failure

Step What to do How to do it

1 Make sure the controller is configured

for Time Proportional output. Make Output Algorithm Set Up group function

prompt OUT ALG (Loop 1) or OUT2 ALG (Loop 2)

= RLY or RLYD.

Refer to Configuration Section.

2 Check the field wiring. Make sure the NO or NC contact wiring is correct.

Refer to Installation Section - for details.

3 Check the output. Put the controller into Manual mode. Vary the

output above and below the present value.

Observe OUT1 indicator (Loop 1) or OUT3

indicator (Loop 2) on the operator interface.

Contact should change state. 0 % open, 100 %

closed. Listen for a click from the relay when the

OUT1 or OUT3 indicator changes state.

4 Check relay. Change relay.

5 Change relay board. Installation instructions supplied with the new

board.

Page 8 of 16 Revision 1

Procedure #5 – Current/Time or Time Current/Proportional

Table -6 explains how to troubleshoot Current/Time or Time/Current Proportional Output

failure.

Table -6 Troubleshooting Current/Time or Time/Current Proportional

Output Failure

Step What to do How to do it

1 Make sure the controller is configured

for Time/Current or Current/Time

Proportional output.

Make Output Algorithm Set Up group function

prompt OUT ALG = TCUR or CURT.

Refer to Configuration Section

2 Check the field wiring. Make sure the NO or NC contact wiring selection

is correct.

Refer to Installation Section for details.

3 Check the relay output. Put the controller into Manual mode. Vary the

output above and below the present value.

Observe OUT1 indicator (Loop 1) or OUT3

indicator (Loop 2) on the operator interface.

Contact should change state. 0 % open, 100 %

closed. Listen for a click from the relay when the

OUT1 or OUT3 indicator changes state.

4 Check the Current Proportional

Output. Put the controller into Manual mode and change

the output from 0 % to 100 % (4-20 mA). Use a DC

milliammeter at the rear terminals to verify the

output.

5 Recalibrate the controller. Refer to Output Calibration Section for details.

6 Change Current Output or Relay

board. Installation instructions supplied with new board.

Page 9 of 16 Revision 1

Procedure #6 – Alarm Relays

ATTENTION

Control Outputs take precedence over Alarms which in turn take precedence over Logic

Gate Outputs. For example, if you select the Loop 2 Output Algorithm as Time

Simplex, then the instrument will use Relay #3 to perform the Time Simplex output.

Therefore, Relay #3 would not be available for Alarm 3 or Logic Gate functions.

The prompts for the Alarm Outputs appear whether or not the alarm relays are

physically present or used for some other function. This allows the Alarm status to be

shown on the display and/or sent via communications to a host computer.

Table 7 explains how to troubleshoot Alarm Relay Output failure.

Table 7 Troubleshooting Alarm Relay Output Failure

Step What to do How to do it

1 Check the alarm configuration

data. If it is correct, check the

field wiring.

Reconfigure if necessary.

Refer to Configuration Section for details.

2 Check that the applicable alarm

relay actuates properly

depending on what you have set

at prompt AxSxTYPE.

If it does, check the field wiring.

If the alarm type is set for PV, place the

controller in manual mode. Vary the input

to raise and lower the PV around the

setpoint. Listen for a click from the relay

as the PV moves in either direction and

note that the proper ALM1 or ALM2 is lit.

EXAMPLE: If the alarm is set for MAN,

put the controller into manual mode. The

alarm light is ON. Put the controller into

automatic mode and the alarm light is

OFF.

3 Check the contacts. Make sure the NO or NC contact wiring is

correct.

Refer to Installation Section for relay

contact information.

4 Change the relay and/or the

relay output board. Installation instructions supplied with the

new relay or board.

Page 10 of 16 Revision 1

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