Archive for category Loop Controllers
People will fire up a new UDC 1/4 DIN loop controller, like a UDC2500 or UDC3200, and discover that the lower display periodically flashes an error code: UNPLUG. But what does it mean? Is something wrong?
A search of the pdf version of the manual hints that the Modbus Ethernet communications is involved:
The Ethernet status screen shows the network status of the Ethernet Link. This may be accessed either via Ethernet or via Infrared Communications. For example, if the Ethernet cable is unplugged, then the instrument cannot send up the EUNPLGED diagnostic message via Ethernet.
But the word UNPLUG is nowhere else in the manual.
Honeywell’s Process Instrument Explorer (PIE) configuration software used for configuring UDC controllers and the UDA analytical controller communicates with the instruments via RS-485, Ethernet, or Infrared (IR).
Since most newer PCs don’t ship with built-in serial ports to connect an IR adapter, you can use a USB-to-RS-232 converter, and then connect using the Actisys serial-to-infrared adapter (ACT-IR220L+). The USB converter will plug directly into your PC’s USB port, but install on a virtual COM port.
Here’s where it gets tricky: That COM port has to match the COM port used in PIE, and PIE doesn’t support ports above COM8.
You’ve heard this phrase before: “It’s simple. But nobody said it would be easy.”
And this is exactly one of those cases.
The Honeywell UDC3500 digital controller can support up to four setpoint programs, the ramp/soak profiles used in batch control operations. But after configuring all four profiles, I was stuck on how to select the one I wanted the controller to use.
There’s no “Program Select” button on the keypad. So I was mystified on how I was going to select my setpoint profile program #3.
RTDs are great temperature sensors – accurate and easy to install. But they are not friendly when it comes to trying to get a single RTD to go to two places, like when an RTD temperature measurement has to go to both a controller and a recorder. People call and ask, “How do I split an RTD signal?” The short answer is, “You can’t.”
An RTD cannot be wired in parallel or in series to a second device. Any RTD input supplies a known, regulated ‘excitation’ current to the RTD. Mixing RTD inputs would mix currents and that’s a Big No-No.
There’s also a lead wire compensation circuit for 3- or 4-wire RTDs that would create problems if a single RTD were connected to two different RTD inputs. There’s just no feasible means of making two RTD analog inputs play nice together.
But all is not lost. There are several ways to achieve your goal.
Industry statistics reveal that a fair percentage of control loops are controlled manually, and are not automated. This fact was brought home last week, when a caller told us he needed “something to adjust the valve position so that the valve stays where it’s been set. And it’s real important that it can’t accidentally go off its own”.
What he was describing is what we call a manual station. It’s a controller where the 4-20mA current output stays fixed where it is until someone pushes buttons on on the front of the controller: up to manually raise the output value, and down to manually lower it. Typically, the output value is displayed for the operator as a digital number from 0 to 100 percent.
So what’s available to fill the bill?
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A customer has several UDC 3200 loop controllers with newly added Ethernet cards. He needed to configure each of the controllers’ IP addresses using Honeywell Process Instrument Explorer (PIE) software. Because the controllers are working in a 24×7 continuous process, he was concerned about how making those changes would affect each controller’s performance.
So he asked me: Would a PIE action of uploading config files from or downloading them back to a controller affect the controller’s performance?
In the past, I’d only ever changed a controller’s IP address when it was on my workbench, not when it was actively controlling a process. So I’d never paid attention to whether PIE communications would affect the controller’s output or its PID action. Since I couldn’t answer the question, I told the customer I’d run a test to find out for sure.
If you use thermocouples in high-temperature applications, you’re aware of the issues thermocouple drift can cause. Thermocouples drift. It’s not a question of IF, it’s a question of WHEN. And thermocouple drift costs processors time and money in processing errors, waste, downtime, and lost production.
Thermocouple drift occurs due to metallurgical changes of the metal alloy elements over the extended use of the sensor. Thermocouples can drift by as much as several degrees per year.