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Product Manual - Lesman Instrument Company

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2. Control Setpoint 0007 007 FP R W 0 to 100 of PV High Limit engineering units Control Setpoint 0008 008 FP R W 0 to 100 of PV Low Limit engineering units Control Output 0087 135 INT R W 0 Direct Direction 1 Reverse 212 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Description Address High Output 000E Limit Low Output 000F Limit Output Deadband 0012 for Time Duplex Output Deadband 0014 for TPSC Output 0013 Hysteresis Failsafe Mode 00D5 Failsafe Output 0028 Level TPSC Power up 00B7 Output TPSC Failsafe 00B8 Output Proportional 0094 Band Units PV High Range 0036 PV Low Range 0037 Data Access Data Range or Type Enumerated Selection Hex Decimal 014 FP R W 5 to 105 of output O15 FP R W 5 to 105 of output 018 FP R W 5 to 25 0 020 FP R W 0 5 to 5 0 019 FP R W 0 0 to 100 0 of PV 213 INT R W 0 Latching 1 Non latching 040 FP R W 0 to 100 183 INT R W 0 Last 1 Failsafe 184 INT R W 0 Motor goes to closed position 0 1 Motor goes to open position 100 148 INT R W 0 Gain 1 Proportional band 149 INT R W 0 Minutes 1 RPM 054 FP R PV High Limit 055 FP R PV Low Limit March 2012 UDC2500 Universal Digital Controller Prod
3. Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal Software Type 009D 157 INT RD READ only UDC2500 37 UDC2500 Software Version OOA7 167 INT RD READ only Value less than 255 10 4 2 SetPoint Program Read Only Information The identifying register addresses listed in Table 10 4 represent some information for SetPoint Programming that is Read only No Writes allowed Table 10 4 SetPoint Program Read Only Information Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal Present SPP OOFB 251 INT RD 1 12 Segment Number Segment Time OOFC 252 INT RD 0 59 Minutes Remaining in Minutes Segment Time OOFD 253 INT RD 0 99 Hours Remaining in Hours Cycles Remaining OOFE 254 INT RD 0 100 Current Cycle OOFF 255 INT RD 0 100 Number March 2012 UDC2500 Universal Digital Controller Product Manual 195 Modbus Read Write and Override Parameters plus Exception Codes 10 5 Setpoints Overview You can use two separate local setpoints in the controller The identifying register addresses listed in Table 10 5 allow you to select which setpoint you want to use and to enter a value in Engineering Units whichever is selected at register address 00A1 for that setpoint via communications Register Addresses Make your selection using regis
4. NONE see Subsection 3 4 Table 6 4 Auxiliary Output Calibration Procedure Numeric Code 50000 CCT Ce O 1 Enter Calibration Vea NY Upper Display CAL Mode Cer Lower Display AUXOUT 50000 until you see 2 Calibrate 0 YH N Youwillsee GOS Upper Display A Value Lower Display ZROVAL 50001 A ory until the desired 0 output is read on the milliammeter use the values shown below depending on the action of your controller Normally this will be the setting that produces 4 mA 3 Calibrate 100 Function To store the 0 value you will see h 4 Upper Display A Value Lower Display SPNVAL 50002 Amor ww until the desired 100 output is read on the milliammeter Normally this will be the setting that produces 20 mA 4 Exit the Calibration Mode The controller stores the span value To exit the calibration mode 158 UDC2500 Universal Digital Controller Product Manual March 2012 Output Calibration 6 4 Restore Output Factory Calibration Procedure Introduction The factory calibration constants for the Current and Auxiliary Outputs are stored in its non volatile memory Thus you can quickly restore the Factory Calibration for those outputs by simply changing the CO RANGE or AO RANGE to the other setting and then changing it back to the original type Refer to Table 6 5 Restore Factory Calibration for procedure ATTENTION A restored factory calibration overwrites any prev
5. tuning may be used Which one is used is selected via the lower display during normal operation For the SLOW selection the controller calculates conservative tuning constants with the objective of minimizing overshoot If the controller determines that the process has appreciable dead time it will automatically default to use Dahlin Tuning which produces very conservative tuning constants The SLOW selection may be useful for TPSC applications as it reduces any hunt problems for the motor For the FAST selection the controller calculates aggressive tuning constants with the objective of producing quarter damped response Depending upon the process this selection will usually result in some overshoot For this reason it may be desireable to enable the FUZZY tune selection See Section 4 12 When Fuzzy tune is enabled it will work to suppress or eliminate any overshoot that may occur as a result of the calculated tuning parameters as the PV approaches the setpoint The TUNE process will cycle the controller s output two full cycles between the low and high output limits while allowing only a very small Process Variable change above and below the SP during each cycle TUNE flashes in the upper display until tuning is completed March 2012 UDC2500 Universal Digital Controller Product Manual 105 Monitoring and Operating the Controller At the end of the tuning process the controller immediately calculates the tuning consta
6. Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code A1S1VA Value in engineering units NOTE 5 Thermocouple Warning means that the instrument has detected that the Thermocouple Input is starting to fail Not valid for other input types NOTE 6 Thermocouple Failing means that the instrument has detected that the Thermocouple Input is in imminent danger of failing Not valid for other input types NOTE 7 For the Digital Input selections DI 1 can be either enabled or disabled in the Options Group See Section 3 12 but DI 2 must be enabled in the Options Group for the alarm to function properly ALARM 1 SETPOINT 1 VALUE This is the value at which you want the alarm type chosen in prompt A1S1TYPE to actuate The value depends on what the setpoint has been configured to represent No setpoint is required for alarms configured for Communications SHED For SP Programming the value is the segment number for which the event applies This prompt does not appear for Alarm on Manual type alarm For example A1S1TYPE MANUAL A1S1HL 1103 HIGH LOW If Setpoint Programming is disabled or if the Alarm Type is not configured for Event On Off ALARM 1 SETPOINT 1 STATE Select whether you want the alarm type chosen in prompt A1S1TYPE to alarm High or Low HIGH ALARM LOW ALARM March 2012 UDC2500 Universal Digital Controller P
7. Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Code POWER LINE FREQUENCY Select whether your controller is operating at 50 or 60 Hertz ATTENTION For controllers powered by 24 Vdc this configuration should be set to the AC line frequency used to produce the 24 Vdc supply Incorrect setting of this parameter may cause normal mode noise problems in the input readings DISPLY DEFAULT DISPLAY For single display units only This setting selects the default parameter shown on the upper display Pressing the LOWER DISPLAY key will cycle through all applicable values One minute after the last press of the display key the display will revert to the display configured here SETPOINT Active Setpoint PV YES Process Variable with lower display prompt PV NO Process Variable with no lower display prompt LWRDSP LOWER DISPLY For dual display units only Select whether the unit uses single or dual display ENAB Enable Dual Display DIS Disable Dual Display Single Display Only LNGUAG LANGUAGE This selection designates the prompt language ENGLISH FRENCH GERMAN SPANISH ITALIAN NUMERIC THERMOCOUPLE DIAGNOSTICS Enable or disable Thermocouple diagnostic messages ENAB Enable Diagnostic Messages DIS Disable Diagnostic Messages 84 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration 3 16 P I E T
8. Key Error appears in the lower display it will be for one of the following reasons March 2012 e Parameter not available or locked out e Not in setup mode press SET UP key first e Individual key locked out UDC2500 Universal Digital Controller Product Manual 93 Monitoring and Operating the Controller 4 5 Monitoring Your Controller 4 5 1 Annunciators The following annunciator functions have been provided to help monitor the controller Table 4 2 Annunciators ALM 1 2 A visual indication of each alarm Blinking 1 indicates alarm latched and needs to be acknowledged by pressing the RUN HOLD key before extinguishing when the alarm condition ends OUT 1 2 A visual indication of the control relays AorM A visual indication of the mode of the controller Dual display model only A Automatic Mode M Manual Mode None F or C A visual indication of the temperature units None No temperature unit annunciator F Degrees Fahrenheit C Degrees Celsius LorR A visual indication of setpoint being used L Local Setpoint is active R RSP or LSP 2 is active The upper display is used to show other annunciator functions TUNE Accutuning in progress RUN SP Program in progress HOLD SP Program on hold CSP Controlling to the Computer Setpoint LOOPBK Loopback Test running 94 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller 4 5 2 Viewing the operating pa
9. March 2012 UDC2500 Universal Digital Controller Product Manual 199 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Range or Description Address Enumerated Selection Hex Decimal Lockout 0084 132 INT R W 0 No Lockout keyboard only 1 Calibration Locked out 2 Configuration Timer Changes to data are always possible via Tuning SP Ramp communications Accutune are read write regardless of this 3 View Tuning and SP configuration Ramp are read write no other parameters are available 4 Maximum Lockout Security Code 0050 080 INT R W 0 to 9999 Man Auto Key OOBF 191 INT R W 0 Disable Lockout 1 Enable Run Hold Key OOEE 238 INT R W 0 Disable Lockout 1 Enable Setpoint Key OOED 237 INT R W 0 Disable Lockout 1 Enable NOTE 1 Writes to these locations are not available when Accutune is enabled 200 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes 10 7 2 SP Ramp Rate Program Table 10 10 lists all the register addresses and ranges or selections for the function parameters in Set up Group Setpoint Ramp Rate Table 10 10 Set up Group Setpoint Ramp Rate Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal SP Ramp 0096 150 INT R W 0 Di
10. OOAF 175 INT R W 0 Setpoint 1 PRY PV with Label 2 PRN PV witout Label TC Diagnostics 009f 159 INT R W 0 Enable 1 Disable 220 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes 10 8 Modbus RTU Exception Codes Introduction When a master device sends a query to a slave device it expects a normal response One of four possible events can occur from the master s query e Slave device receives the query without a communication error and can handle the query normally It returns a normal response e Slave does not receive the query due to a communication error No response is returned The master program will eventually process a time out condition for the query e Slave receives the query but detects a communication error parity LRC or CRC No response is returned The master program will eventually process a time out condition for the query e Slave receives the query without a communication error but cannot handle it i e request is to a non existent coil or register The slave will return with an exception response informing the master of the nature of the error Illegal Data Address The exception response message has two fields that differentiate it from a normal response Function Code Field In a normal response the slave echoes the function code of the original query in the function cod
11. RESET e Alarm 1 relay is inactive e The time display shows the time out period e The time out period can be changed at this time using the Aor W keys e The Timer is ready to be activated 104 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller 4 11 Accutune lll Introduction Accutune III TUNE may be used for self regulating and single integrating processes This autotuning method is initiated on demand typically at initial start up There are no other requirements necessary such as prior knowledge to the process dynamics or initial or post tune process line out to setpoint or manual output Also the setpoint value is not required to change in order to initiate the tuning process but the controller must be in the Automatic mode to start tuning The process need not be in a Static lined out state and may be dynamic changing with a steady output Configuration check Make sure e TUNE has been enabled see to Subsection 3 6 Accutune Set Up Group for details Tuning indicators TUNE will flash in the upper display until tuning is completed Operation The TUNE Accutune II algorithm provides user friendly on demand tuning in this controller No knowledge of the process is required at start up The operator simply initiates the tuning while in the automatic mode Once Accutune III has been enabled in the TUNE setup group either SLOW or FAST
12. 0 1 P SP TRK NONE PROC RS 2 04 PWR UP 806 MAN 0 ALSP 1 Parameter Definition TWO LOCAL SETPOINTS T his selection lets you switch between two local setpoints using the SETPOINT SELECT key REMOTE SETPOINT SOURCE This selection lets you switch between the local and remote setpoints using the SETPOINT SELECT key NONE No remote setpoint INPUT 2 Remote Setpoint is Input 2 SETPOINT TRACKING The local setpoint can be configured to track either PV or RSP as listed below Not configurable when Auto Bias is set ATTENTION For selections other than NONE LSP is stored in nonvolatile memory only when there is a mode change e when switching from RSP to LSP or from Manual to Automatic If power is lost then the current LSP value is also lost NO TRACKING TIf local setpoint tracking is not configured the LSP will not be altered when transfer from RSP to LSP is made PROCESS VARIABLE PV Local setpoint tracks the PV when in manual RSP Local setpoint tracks remote setpoint when in automatic When the controller transfers out of remote setpoint the last value of the remote setpoint RSP is inserted into the local setpoint POWER UP CONTROLLER MODE RECALL This selection determines which mode and setpoint the controller will use when the controller restarts after a power loss MANUAL LSP At power up the controller will use manual mode with the local setpoint
13. Bit 5 Alarm 12 Event Bit 6 Alarm 21 Event Bit 7 Alarm 22 Event Alarm 1 Blocking 00CA 202 INT 0 Disable 1 Block 1 2 Block 2 3 Block 1 2 218 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Diagnostic Alarm 009A 154 INT R W 0 Disable 1 Alarm 1 2 Alarm 2 March 2012 UDC2500 Universal Digital Controller Product Manual 219 Modbus Read Write and Override Parameters plus Exception Codes 10 7 12 Display Table 10 20 lists all the register addresses and ranges or selections for the function parameters in Set up Group Display Table 10 20 Set up Group Display Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Decimal Point 009B 155 INT R W 0 XXXX Fixed Location 1 XXX X Floating decimal point to one 2 XX XX Floating decimal point to two Temperature 0081 129 INT R W 0 F Units 1 C 2 None Power 00A6 166 INT R W 0 60 Hertz Frequency 1 50 Hertz Language 00CO 192 INT R W 0 English Displays 1 French 2 German 3 Spanish 4 Italian 5 Numeric Lower Display OOAE 174 INT R W 0 Enable Enable 1 Disable Lower Display
14. Communications Failure 172 173 Communications Interface 10 Composite Wiring Diagram 21 Computer Setpoint 194 Computer Setpoint Ratio 75 Configuration 32 Configuration Parameters 196 March 2012 Index Configuration Procedure 34 Configuration Prompt Hierarchy 33 Control Algorithm 46 Control And Alarm Relay Contact Information 14 Control Modes 100 Control Relays 14 Control Set Up Group 61 67 73 Control Alarm Circuit Wiring 17 Controller Failure Symptoms 164 Controller Grounding 17 Controller Output Types 9 Current Duplex 52 Current Output 27 Current Output Calibration 152 Current Output Calibration Procedure 153 Current Output Failure 166 Current Simplex 52 Current Time Duplex 52 Current Time Or Time Current Proportional Output Failure 169 Customer Support 160 Cycle Time Cool 37 Cycle Time Heat 37 D Deadband 65 Decimal Places 82 Demand Tuning 43 Diagnostic Alarm 81 Diagnostic Message 95 Digital Input Remote Operation 124 Digital Input Selections 69 Digital Inputs 8 Digital Inputs Option Connections 30 Dimensions 15 Direct Acting Control 64 Displays 3 Dual Electromechanical Relay Option Output 27 Duplex Control 106 108 E Elapsed Time 103 Electrical Considerations 17 Electrical Noise Precautions 17 Electromechanical Relay Output 24 Email Configuration Screen 85 Emissivity 58 End Segment Number 119 Environmental And
15. PV RATE OF CHANGE PVRT The amount of PV change in one minute in engineering units LOOP BREAK ALARMS BRAK The timer value may be changed only for controllers configured for ON OF March 2012 UDC2500 Universal Digital Controller Product Manual 113 Monitoring and Operating the Controller see Operation Pros Rem Lower Display A1S1VA Alarm 1 Setpoint 1 A1S2VA Alarm 1 Setpoint 2 A2S1VA Alarm 2 Setpoint 1 A2S2VA Alarm 2 Setpoint 2 NOTES With 3 position step control alarms set for output will not function MAN RSP AND FSAF selections do not have setpoint values 3 Change a value To change any alarm setpoint value in the upper display 4 Return to Normal Display 4 15 Three Position Step Control Algorithm Introduction The Three Position Step Control algorithm allows the control of a valve or other actuator with an electric motor driven by two controller output relays one to move the motor upscale the other to move it downscale without a feedback slidewire linked to the motor shaft Estimated Motor Position The Three Position Step control algorithm provides an output display OT which is an estimated motor position since the motor is not using any feedback e Although this output indication is only accurate to a few percent it is corrected each time the controller drives the motor to one of its stops 0 or 100 e It avoids all the control problems associated with the feed
16. Register Count Floating Point Data CRC16 This is the response to the above request Response Message 02 14 06 05 06 3F CO 00 00 CRC16 Where 02 Address 14 Function Code 20 14 Hex 06 Byte Count 05 Sub Message Length 06 Reference Type IEEE Floating Point 3F C0 0000 1 50 Value of Proportional Band CRC16 March 2012 UDC2500 Universal Digital Controller Product Manual 187 Modbus RTU Function Codes Example 2 The following is another example of a request and response message using Function code 20 Request Message Read LSP 1 ID Tag 39 and LSP 2 ID Tag 53 02 14 OE 06 00 03 00 27 00 02 06 00 03 00 35 00 02 CRC16 Where 02 Address 14 Function Code 20 14 Hex OE Byte Count 06 Reference Type IEEE Floating Point 00 03 File Number Access Data Value 00 27 Register Address Standard Access LSP 1 ID Tag 39 00 02 Register Count to read Floating Point Data 06 Reference Type IEEE Floating Point 00 03 File Number Access Data Value 00 35 Register Address Standard Access LSP 2 ID Tag 53 00 02 Register Count to read Floating Point Data CRC16 This is the response to the above request Response Message 02 14 0C 05 06 43 C8 00 00 05 06 44 60 00 00 CRC16 Where 02 Address 14 Function Code 20 14 Hex 0C Byte Count 05 Data Byte Count Sub Message Length 06 Reference Type IEEE Floating Point 43 C8 0000 400 0 Value of Local Setpoint 1 05 Data
17. Selection TC RTD mV 0 5V 1 5V 0 20mA 4 20mA 0 10V None 0 5V 1 5V 0 20mA 4 20mA TABLE IV Options Approvals CE UL and CSA Standard CE UL CSA and FM CE Only Stainless Steel Customer ID Tag 3 lines w 22 characters line Future Options TABLE V Product Manuals Product Information on CD English English Hard Copy Manual 51 52 25 127 Manuals French Hard Copy Manual 51 52 25 127 FR German Hard Copy Manual 51 52 25 127 DE Italian Hard Copy Manual 51 52 25 127 IT Spanish Hard Copy Manual 51 52 25 127 SP Certificate mone Certificate of Conformance F3391 TABLE VI No Selection RESTRICTIONS ee Available Only With Not Available With Restriction Letters _Available Only With _ Table Selection Table Limit Controller Restrictions Comments 1 FM approved units with communications are limited to read only 2 UL listed for regulatory use only ORDERING INSTRUCTIONS These are provide as guidance for ordering such as those listed 1 Part numbers are provided to facilitate Distributor Stock 2 Orders may be placed either by model selection or by part number 3 Part numbers are shown within the model selection tables to assist with compatibility information 4 Orders placed by model selection are systematically protected against incompatibility 5 Compatibility assessment is the responsibility of the purchaser for orders placed by part number 6 Items labeled as N A are not av
18. Solid state relays ATTENTION Cycle times are in either second or 1 3 second increments depending upon the configuration of RLYTYP in the Output Algorithm Set Up group CYCLE TIME 2 COOL is the same as above except it applies to Duplex models as the cycle time in the COOL zone of Heat Cool applications or for the second set of PID constants CYC2T2 Electromechanical relays CT2 X3 Solid state relays ATTENTION Cycle times are in either second or 1 3 second increments depending upon the configuration of RLYTYP in the Output Algorithm Set Up group SECURITY CODE The level of keyboard lockout may be changed in the Set Up mode Knowledge of a security code may be required to change from one level to another This configuration should be copied and kept in a secure location NOTE The Security Code is for keyboard entry only and is not available via communications ATTENTION Can only be changed if LOCK selection is NONE LOCKOUT applies to one of the functional groups Configuration Calibration Tuning Accutune DO NOT CONFIGURE UNTIL ALL CONFIGURATION IS COMPLETE NONE No lockout all groups are 38 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code read write CALIBRATION Al groups are available for read write e
19. The file number word contains the register number from the register address structure shown in Table 9 1 and Table 9 2 Although the register address structure tables indicate up to 13 data registers are available for access only register address 3 is currently supported Register Address The register address is used to designate the tag ID number for the parameter being accessed The register address is made up of two bytes the MSB 00 always The LSB contains the RS422 tag ID number The tag ID numbers represent the parameter s register address es See Section 10 for the tag ID numbers Table 9 4 Register Address Format for Function Code 21 Register Register Address es Address es Dec Hex 001 to 125 0001 to 007D analog formatted data 2 registers IEEE 32 bit floating point 128 to 215 0080 to 00D7 integer formatted data amp 255 amp OOFF 2 registers IEEE 32 bit floating point Unrestricted Registers As mentioned previously all register data is stored in the EEROM of this instrument with some exceptions These exceptions were made to allow write access to override information The registers which are designated as Override values are listed below These registers do not have restrictions on the number of writes ID Tag Register Number UDC Usage 125 7Dh Computer Setpoint Restrictions on Parameter Numbers in One Message The maximum number of writeable parameters per write request is 1 190
20. is configured for Three Position Step control Check the field wiring Check the output Check whether the motor drives in both directions Check whether the motor drives in either direction If the motor does not drive in either direction check the motor If the motor drives in one direction but not the other go to Step 6 Make sure the output relays are actuating properly Change the two Output Relays or the Dual Relay Board depending upon unit Make Output Algorithm Set Up group function prompt OUT ALG TPSC Refer to Section 3 8 Refer to Section 2 Installation for details Put the controller into Manual mode and change the output from 0 to 100 Remove controller and short out Output 1 or Output 2 The motor should go to either open or closed If it does controller is ok If not repeat Step 1 Refer to the motor instructions Put the controller into Manual mode Vary the output above and below the present value Observe OT in the Lower Display and the Relay Annunciators on the operator interface If they are not working properly check the field wiring then go to Step 5 If they are go to Step 7 Installation instructions supplied with the new relays or board 170 UDC2500 Universal Digital Controller Product Manual March 2012 Procedure 4 Troubleshooting Service Table 7 8 explains how to troubleshoot Time Proportional Output failure Table 7 8 Troubleshooting Time
21. 071 FP R W 99 59 0 99 Hrs 0 59 Min 072 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degrees Minute 073 FP R W Within Setpoint Limits 004A 074 FP R W 99 59 0 99 Hrs 0 59 Min March 2012 UDC2500 Universal Digital Controller Product Manual 203 Modbus Read Write and Override Parameters plus Exception Codes 10 7 3 Accutune Table 10 11 lists all the register addresses and ranges or selections for the function parameters in Set up Group Accutune Table 10 11 Set up Group Accutune Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Fuzzy Overshoot 00C1 193 INT R W 0 Disabled Suppression 1 Enabled Accutune Enable 0098 152 INT R W 0 Accutune Disabled 1 Tune Accutune Duplex El 223 INT R W 0 Manual selection 1 Auto 2 Disable blend Accutune Error 0097 151 INT R W 0 None Read only 3 Process Identification failed 4 Accutune aborted on command 5 Running 204 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes 10 7 4 Algorithm Table 10 12 lists all the register addresses and ranges or selections for the function parameters in Set up Group Algorithm Table 10 12 Set up Group Algorithm Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Dec
22. 1 Parts Identification Key Part Number Description Number 51453143 501 Bezel Assembly and Bezel Gasket 51452758 502 Display Keyboard with IR 3 51452822 502 Power Output PWA 90 250 Vac Operation DIA Power Output PWA 24 Vac dc Operation 4 51452810 501 Auxiliary Output Digital Input RS 422 485 Communications PWA Gales Auxiliary Output Digital Input Ethernet Communications PWA 5 51452801 503 MCU Inputs PWA with 2nd Input and IR for Controllers DM ed MCU Inputs PWA with IR for Limit Controllers Output 1 2 30755306 501 e Electro Mechanical Relay 30756679 501 e Open Collector Output PWA 30756725 501 e Solid State Relay 51452804 501 e Current Output PWA 51452807 501 e Dual Electromechanical Relay PWA 51452759 501 Case Assembly including Mounting Kit with 4 brackets amp screws Output 3 30755306 501 e Electro Mechanical Relay 30756679 501 e Open Collector Output PWA 30756725 501 e Solid State Relay Table 8 2 Parts Not Shown Table 8 3 Software Upgrades see Section 7 9 50004634 501 Dual Display and Manual Auto 50004634 502 Dual Display Manual Auto and Set Point Programming SPP March 2012 UDC2500 Universal Digital Controller Product Manual 181 Parts List 8 2 Removing the chassis Insert thin screwdriver under tabs and twist slightly and gently to disengage front Using a thin screwdriver gently twist the screwdriver to pry the side tabs from the front face Pry just enough to release
23. 184 to149 25 202 ohms 156 910 ohms 200 ohms 300 to 1200 184 to649 50 404 ohms 658 578 ohms 500 ohms 300 to 1200 184 to649 126 012 ohms 1646 445 ohms Linear Milliamps 4 to 20 mA 4 00 mA 20 00 mA O to 20 mA 0 00 mA 20 00 mA Millivolts Oto 10mV 0 00 mV 10 00 mV Oto 50mV 0 00 mV 50 00 mV 0 to 100 mV 0 00 mV 100 00 mV Volts 1to 5 Volts 1 00 Volts 5 00 Volts Oto 5 Volts 0 00 Volts 5 00 Volts 0 to 10 Volts 0 00 Volts 10 00 Volts The Factory Calibrated millivolt values for the Thermocouple Differential Input are for a pair of J thermocouples at an ambient temperature mean of 450 F 232 C Other thermocouple types and ambient temperature means may be accomplished via Field Calibration of the input with the range value limits being 4 mV to 16 mV for the zero and span values The range values for Radiamatic Type RI are customer configurable within the limits shown March 2012 UDC2500 Universal Digital Controller Product Manual 139 Input Calibration Table 5 2 Voltage and Milliamp Equivalents for Input 2 Range Values Sensor Type PV Input Range Range Values Linear Milliamps 4 to 20 mA 4 00 mA 20 00 mA 0 to 20 mA 0 00 mA 20 00 mA Volts 1to 5 Volts 1 00 Volts 5 00 Volts Oto 5 Volts 0 00 Volts 5 00 Volts Oto 2 Volts 0 00 Volts 2 00 Volts 5 3 Preliminary Information Disconnect the Field Wiring Tag and disconnect any field wiring connected to the input 1 or 2 terminals on the rear of
24. 21 Worksheet 118 March 2012 Sales amp Service 14 Sales Service Sales and Service For application assistance current specifications pricing or name of the nearest Authorized Distributor contact one of the offices below ASIA PACIFIC EMEA NORTH AMERICA SOUTH AMERICA TAC Honeywell Process Solutions Honeywell Process Solutions Honeywell do Brasil amp Cia hfs tac Phone 80012026455 or 44 Phone 1 800 423 9883 Phone 55 11 7266 1900 support honeywell com 0 1202645583 Or 1 800 343 0228 FAX 55 11 7266 1905 FAX 44 0 1344 655554 Australia i Honeywell Limited Email Sales Email Sales Email Sales Phone 61 7 3846 1255 SC Cp appsS ask ssc honeywell com ask ssc honeywell com FAX 61 7 3840 6481 salespa62 honeywell com Toll Free 1300 36 39 36 ae el 9 Toll Free Fax TAC TAC 1300 36 04 70 TAC hfs tac hfs tac hfs tac support honeywell com support honeywell com China PRC Shanghai support honeywell com Honeywell China Inc Phone 86 21 5257 4568 Fax 86 21 6237 2826 Singapore Honeywell Pte Ltd Phone 65 6580 3278 Fax 65 6445 3033 South Korea Honeywell Korea Co Ltd Phone 822 799 6114 Fax 822 792 9015 March 2012 UDC2500 Universal Digital Controller Product Manual 229 Honeywell Honeywell Process Solutions 1860 West Rose Garden Lane 51 52 25 127 Rev 6 Phoenix Arizona 85027 March 2012 www honeywellprocess com 2012 Honeywell International Inc
25. 5 Configuration to do the setpoint program Make sure SPRATE and SPRAMP are disabled Fill out the worksheet Refer to the example in Figure 4 3 and draw a Ramp Soak Profile on the worksheet provided Figure 4 4 and fill in the information for each segment This will give you a record of how the program was developed Operation Refer to Table 4 26 Run Monitor the program Program Contents Table 4 25 lists all the program contents and a description of each Table 4 25 Program Contents Ramp time or rate A ramp segment is the time or rate of change it takes to change the setpoint segments to the next setpoint value in the program e Ramps are odd number segments Segment 1 will be the initial ramp time Ramp time is determined in either TIME Hours Minutes Range 0 99 hr 59 min or EU M Degrees Minute Range 0 to 999 EU H Degrees Hour The selection of time or rate is made at prompt RP UNIT Set this prompt before entering any Ramp information March 2012 UDC2500 Universal Digital Controller Product Manual 119 Monitoring and Operating the Controller Ramp unit Soak segments Start segment number End segment number Recycle number Guaranteed soak PV Start 120 ATTENTION Entering 0 will imply an immediate step change in setpoint to the next soak The ramp unit selection determines the engineering units for the ramp segments The selections are TIME Hours
26. 7 4 Table 7 4 Controller Failure Symptoms Upper Lower Indicators Controller Probable Trouble Display Display Output Cause shooting Procedure Upper Lower Indicators Controller Probable Trouble Display Display Output Cause shooting Procedure Blank Blank Off None Power Failure 1 OK OK Current 2 Proportional Output OK Displayed OK Controller Three Position 3 Output Output Step Control disagrees disagrees Output with Controller with Displayed OK Output OK Output Time Proportional 4 Output OK OK Current Time 5 Proportional Output OK OK OK External Alarm Malfunction in 6 function does alarm output not operate properly Display does not change when a key is pressed Keyboard 7 Malfunction Controller fails to go into Slave operation during communications Communications 8 Failure OK Displayed OK Controller Auxiliary Output 9 Output Auxiliary Output disagrees with disagrees Auxiliary Output with Displayed Auxiliary Output 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 March 2012 UDC2500 Universal Digital Controller Product Manual 167 Troubleshooting Service If the symptom still persists refer to the installation section in this manual to ensure proper installation and proper use of the con
27. Byte Count Sub Message Length 06 Reference Type IEEE Floating Point 44 600000 896 0 Value of Local Setpoint 2 CRC16 188 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus RTU Function Codes 9 4 Function Code 21 15h Write Configuration Reference Data Introduction Function Code 21 15 Hex is used in this instrument to allow writes of integer and floating point values to the configuration database and override values The configuration database of this instrument is located in EEROM The override values are stored in RAM Integer format is used to write to Digital configuration items Floating Point format is used to write to Analog configuration items as defined by the configuration ID tags Write Restrictions Care should be taken not to exceed the 100 000 write limit of the EEROM Request and Response Formats The Request and Response formats for Function code 21 15 Hex are shown below Details for each block reference follow Request Message Format The register address is interpreted as the tag ID configuration number For Infrared Transactions add three BOFs COhex at the beginning of each message and one EOF FFhex at the end of each message Reference Type Definitions The Reference Type definition is always 06 See examples in Subsection 9 4 1 March 2012 UDC2500 Universal Digital Controller Product Manual 189 Modbus RTU Function Codes File Number
28. Code Code RLY TYP RELAY CYCLE TIME INCREMENT selection is used only for Time Simplex and Duplex output configurations This configuration sets the increment size of the relay cycle times in the Tuning and Tuning 2 Set Up groups ELECTROMECHANICAL RELAY Cycle time in one second increments SOLID STATE RELAY Cycle time in 1 3 second increments This is useful for solid state relay applications that require shorter cycle times DO NOT use this setting unless cycle times of less than 1 second are required ATTENTION The Lockout selection must be set to NONE in order to view this selection MOTOR TIME Appears only when TPSC Three Position Step Control is selected as the Control Algorithm This is the time it takes the motor to travel from 0 to 100 fully closed to fully open This time can usually be found on the nameplate of the motor 5 to 1800 seconds March 2012 UDC2500 Universal Digital Controller Product Manual 55 Configuration 3 9 Input 1 Set Up Group Introduction This data deals with various parameters required to configure Input 1 Function Prompts Table 3 9 INPUT 1 Group Numeric Code 600 Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code IN1TYP INPUT 1 ACTUATION TYPE This selection determines what actuation you are going to use for Input 1 B B Thermocouple E H E Thermoco
29. Duplex OOBE 190 INT 0 1 second increments 1 1 3 second increments 075 INT 5 to 1800 seconds 0099 153 INT 0 Full 100 1 Split 50 OOEA 235 INT 0 4 20 mA 1 0 20 mA UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes 10 7 6 Input 1 Table 10 14 lists all the register addresses and ranges or selections for the function parameters in Set up Group Input 1 Table 10 14 Set up Group Input 1 Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Input 1 Type 00A8 168 INT R W 1 BTC 2 ETCH 3 ETCL 4 JTCH 5 JTCM 6 JTCL 7 KTCH 8 KTCM 9 KTCL 10 NNMH 11 NNML 12 Nicrosil H TC 13 Nicrosil L TC 14 RTC 15 STC 16 TTCH 17 TTCL 18 W TC H 19 WTCL 20 100 PT RTD 21 100 PT LO RTD 22 200 PT RTD 23 500 PT RTD 24 Radiamatic RH 25 Radiamatic RI 26 0 20 mA 27 4 20 mA 28 0 10 mV 29 0 50 mV 30 100 mV 31 0 5 Vdc 32 1 5 Vdc 33 0 10 Vdc 34 Unused 35 Unused 36 Thermocouple Differential 37 PR40 PR20 Thermocouple ATTENTION Changing the Input Type will result in the loss of Field Calibration values and will restore the Factory Calibration values March 2012 UDC2500 Universal Digital Controller Product Manual 207 Modbus Read Write and Override Parameters plus Exception Codes Para
30. E OK Mode Auto LSP1 Alarm Inactive Digital Inputs Inactive Digital Inputs Status DK A A Device Type UDC3500 014 V1 Please wait Upload is in Progress Figure 4 6 Loop Data Maintenance Screen The Loop Data screen allows you to see the current status of the process loop The OP1 OP2 and OP3 windows indicate the status of the current outputs If a current output is not installed the OP status for that output is always OK The Alarms and Digital Inputs buttons allow you to see the current status of each alarm setpoint and digital input March 2012 UDC2500 Universal Digital Controller Product Manual 127 Monitoring and Operating the Controller Loop Data Alarm Details This screen appears when you click on the Alarm button on the Loop Data Maintenance Screen and shows the status of each alarm setpoint NONE in the Type column indicates that the alarm is disabled Highlighted alarms are currently active An asterisk indicates that the alarm has changed state since the last communications transaction For this instrument the Alarm On and Alarm Off columns will always be blank See Section 3 14 for other information about configuring Alarms Maintenance Data Alarm Details eS Screen shows Alarm History Active Alarms are highlighted An indicates that Alarm status has changed since last update Screen refreshes automatically if the communication link is selected as AS485 or Ethernet Tool
31. Low Output Limits are disregarded and the operator can change the output value using the increment and decrement keys to the limits allowed by the output type 0 to 100 for a time proportioning output or 5 to 105 for a current output Manual Mode not available with Single Display model March 2012 UDC2500 Universal Digital Controller Product Manual 101 Monitoring and Operating the Controller 4 8 2 What happens when you change modes Table 4 8 Changing Control Modes Dual Display Only Manual to The Local Setpoint is usually the value previously stored as the Local Setpoint Automatic Local PV tracking is a configurable feature which modifies this For this configuration Setpoint when the controller is in manual mode the local setpoint value tracks the process variable value continuously Manual or Auto The Remote Setpoint uses the stored ratio and bias to calculate the control Local to Automatic setpoint Remote SP Automatic Remote If configured for local setpoint tracking RSP when the controller transfers out of Setpoint to Manual remote setpoint the last value of the remote setpoint is inserted into the local or Auto Local setpoint Setpoint If LSP tracking is not configured the local setpoint will not be altered when the transfer is made 4 9 Setpoints Introduction You can configure the following setpoints for the UDC2500 controller e A Single Local Setpoint e 2 Local Setpoints e a Local Setpoint
32. Minimum and Maximum Range Values 138 5 3 Preliminary Information 140 5 4 Input 1 Set Up Wiring 141 5 5 Input 1 Calibration Procedure 145 5 6 Input 2 Set Up Wiring 147 5 7 Input 2 Calibration Procedure 148 5 8 Restore Factory Calibration 150 March 2012 UDC2500 Universal Digital Controller Product Manual 137 Input Calibration Calibration Steps Use the following steps when calibrating an input 1 Find the minimum and maximum range values for your PV input range from Table 5 1 2 Disconnect the field wiring and find out what equipment you will need to calibrate 3 Wire the calibrating device to your controller according to the set up wiring instructions for your particular input Subsection 5 4 or 5 6 4 Follow the calibration procedure given for Input 1 or Input 2 Subsection 5 5 or 5 7 5 2 Minimum and Maximum Range Values Select the Range Values Calibrate the controller for the minimum 0 and maximum 100 range values of your particular input type Two input controllers will need to have each input calibrated separately Select the Voltage Current or Resistance equivalents for 0 and 100 range values from Table 5 1 and Table 5 2 Use these values when calibrating your controller Table 5 1 Voltage Milliamp and Resistance Equivalents for Input 1 Range Values Sensor Type PV Input Range Range Values Thermocouples per ITS 90 B O to 3300 18 to
33. Minutes XX XX Range 0 99 hr 0 59 min e EU H Degrees Hour OR EU M Degrees Minute Range 0 999 A soak segment is a combination of soak setpoint value and a soak duration time Soaks are even number segments Segment 2 will be the initial soak value and soak time The soak setpoint range value must be within the setpoint high and low range limits in engineering units Soak time is the duration of the soak and is determined in TIME Hours Minutes Range 0 99 hr 59 min The start segment number designates the number of the first segment Range 1 to 11 The end segment number designates the number of the last segment it must be a soak segment even number Range 2 to 12 The recycle number allows the program to recycle a specified number of times from beginning to end Range 0 to 99 All soak segments can have a deviation value of from 0 to 99 specified by SOK DEV which guarantees the value for that segment Guaranteed soak deviation values gt 0 guarantee that the soak segment s process variable is within the deviation for the configured soak time Whenever the deviation is exceeded soak timing is frozen There are no guaranteed soaks whenever the deviation value is configured to O that is soak segments start timing soak duration as soon as the soak setpoint is first reached regardless of where the process variable remains relative to the soak segment The soak deviation value is the num
34. Operating Conditions 11 UDC2500 Universal Digital Controller Product Manual 225 Equipment You Will Need To Calibrate 139 Error Codes 109 Error Messages 95 Estimated Motor Position 113 Ethernet Communications Address 133 134 Ethernet Configuration Screen 84 Ethernet Connection 131 Ethernet Status 130 Ethernet TCP IP 220 Ethernet TCP IP Communications Interface 10 External Interface Option Connections 29 30 External Setpoint Program Reset 70 External Wiring 18 F Factory Calibration 149 156 Failsafe Function Prompt 114 115 Failsafe Manual Mode 161 Failsafe Mode 66 Failsafe Mode 115 Failsafe Output Value 65 Failsafe Output Value 114 Failsafe Output Value For Restart After A Power Loss 114 Field Wiring 139 Filter 57 60 Floating Point Parameter Type 181 Function Code 20 182 Function Code 21 186 Function Codes 20 And 21 180 Function Prompts 33 Fuzzy Overshoot Suppression 43 110 Fuzzy Overshoot Suppression 44 G Gain 35 Gain 2 36 Guaranteed Soak 119 H Hotstart 71 Hysteresis Output Relay 65 I J Infrared Communications 4 Infrared Communications 10 Infrared Communications 73 Input 1 Actuation Type 55 59 Input 1 And Input 2 Wiring Terminals 139 Input 1 Calibration Procedure 144 Input 1 Connections 23 Input 1 High Range Value 56 60 226 UDC2500 Universal Digital Controller Product Manual Input 1 Low Range Value 57 60 Input 1 S
35. Output High Scaling Factor will produce a low end output 4 mA or 0 output A positive deviation equal in magnitude to the Auxiliary Output Low Scaling Factor will produce a high end output 20 mA or 100 FOR EXAMPLE Input 1 Type T High Thermocouple PV range 300 F to 700 F PV span 1000 F Deviation Range 1000 F to 1000 F Auxiliary Output Low Scale Value 0 0 Auxiliary Output High Scale Value 1000 If PV 500 F and SP 650 F then Deviation Display 150 F which is 7 5 of the Deviation Range so Auxiliary Output 50 7 5 42 5 OUTPUT Represents the displayed controller output in percent Cannot be used with Three Position Step Control SETPOINT Represents the value of the setpoint currently in use and is shown in the same units as those used by the PV LOCAL SETPOINT ONE Auxiliary output represents Local Setpoint 1 regardless of active setpoint LOCAL SETPOINT TWO Auxiliary output represents Local Setpoint 2 regardless of active setpoint Value in AUXILIARY OUTPUT LOW SCALING Engineering Units FACTOR This is a value in engineering units used to represent all AUX OUT parameters except Output For Output this is a value in percent and can be any value between 5 and 105 However keep in mind that relay output types can only be scaled 0 to 100 March 2012 UDC2500 Universal Digital Controller Product Manual 69 Configuration Fu
36. PCT 0 FREQ 60 100 PCT 100 LWRDSP DIS DIG IN 1 NONE DISPLY SP DIG1 CMB DIS LNGUAG ENGL DIG IN 2 NONE TCDIAG DIS DIG2 CMB DIS COM COMADR Disable Ethernet MAC Add Ss COMSTA 0 Accessible P Address 10 0 0 IRENAB Enable Via PIE Subnet Mask 2 BAUD 9600 Tool 225 22 TX_DLY 30 5 225 0 WS FLT FP B Default Gate SDENAB Enable To Email 0 0 0 0 SHDTIM 0 SMTP Add Ene SDMODE Last Alarm l 0 0 0 0 SHD SP LSP Email Subj NONE UNITS PCT B CSRATIO 1 0 CSP_BI 0 LOOPBK Disable March 2012 UDC2500 Universal Digital Controller Product Manual 89 Monitoring and Operating the Controller 4 Monitoring and Operating the Controller 4 1 Overview Introduction This section gives you all the information necessary to help you monitor and operate your controller including an Operator Interface overview how to lockout changes to the controller entering a security code and monitoring the displays What s in this section The following topics are covered in this section fh ene a O N 4 4 Lockout Feature 4 22 P I E Tool Maintenance Screens 4 23 Configuring your Ethernet Connection 132 alu na ra a nN Wile Re N nN 90 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller 4 2 Operator Interface Introduction Figure 4 1 is a view of the Operator Interface Figure 4 1 Operator Interface 4 3 Entering a Security Code Introduction The level of keyboar
37. Program start segment Check SP Program configuration subsection 3 5 number is less than ending segment Set up Group SPPROG function prompts number STRSEG and ENDSEC TCWARN The Thermocouple is starting to This diagnostic message means that the burnout controller has detected that the thermocouple is starting to burnout This error message may also be created if the resistance of the wires used to connect the thermocouple to the instrument is above 100 ohms TCFAIL The Thermocouple is in imminent This diagnostic message means that the danger of burning out controller has detected that the thermocouple will soon fail User should consider replacing the thermocouple as soon as possible This message will also be generated if the resistance of the wires used to connect the thermocouple to the instrument is above 180 ohms OUT1FL Current Output is less than 3 5 mA The current output is open circuit Check the field wiring See Procedure 2 OUT2FL Auxiliary Output is less than 3 5 mA The auxiliary output is open circuit Check the field wiring See Procedure 10 166 UDC2500 Universal Digital Controller Product Manual March 2012 Troubleshooting Service 7 6 Controller Failure Symptoms Introduction In addition to the error message prompts there are failure symptoms that can be identified by noting how the controller displays and indicators are reacting Symptoms Compare your symptoms with those shown in Table
38. See examples in Subsection 9 3 1 File Number The file number word contains the register number from the register address structure tables on page 3 Although the register address structure tables indicate up to 13 data registers are available for access only register address 3 is currently supported Register Address The register address word represents the tag ID number for the parameter s being accessed The register address word is made up of two bytes the MSB 00 always The LSB contains the tag ID number The tag ID numbers represent the parameter s register address es See Section 3 for the tag ID numbers Table 9 3 Register Address Format for Function Code 20 Register Register Address es Address es Decimal Hex 001 to 125 0001 to 007D analog formatted data 2 registers IEEE 32 bit floating point 128 to 255 0080 to OOFF integer formatted data 1 register 16 bit integer 186 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus RTU Function Codes 9 3 1 Read Configuration Examples Example 1 The following is an example of a request to read the Gain 1 value using Function code 20 Request Message Read Gain 1 ID Tag 001 02 14 07 06 00 03 00 01 00 02 CRC16 Where 02 Address 14 Function Code 20 14 hex 07 Byte Count 06 Reference Type 00 03 File Number Access Data Value 00 01 Register Address Standard Access Gain 1 Tag ID 1 0002
39. Universal Digital Controller Product Manual 81 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition E e Numeric Code Code Esa LATCHING ALARM OUTPUT 1 Alarm output 1 can be configured to be Latching or Non latching NO LAT Non latching LATCH Latching ATTENTION When configured for latching the alarm will stay active after the alarm condition ends until the RUN HOLD key is pressed ALARM BLOCKING Prevents nuisance alarms when the controller is first powered up The alarm is suppressed until the parameter gets to the non alarm limit or band Alarm blocking affects both alarm setpoints DISABLE Disables blocking AL1 Blocks alarm 1 only AL2 Blocks alarm 2 only AL12 Blocks both alarms ATTENTION When enabled on power up or initial enabling via configuration the alarm will not activate unless the parameter being monitored has not been in an alarm condition for a minimum of one control cycle 167 ms BLOCK DIAGAL 82 UDC2500 Universal Digital Controller Product Manual March 2012 DIAGNOSTIC Monitors the Current Output and or Auxiliary Output for an open circuit condition If either of these two outputs falls below about 3 5 mA then an Alarm is activated This configuration is in addition to whatever was selected for AxSxTYPE DISABLE Disables Diagnostic Alarm ALARM 1 Alarm 1 is diagnostic alarm ALARM 2 Alarm 2
40. any obvious shipping damage and report any damage due to transit to the carrier e Make sure a bag containing mounting hardware is included in the carton with the controller e Check that the model number shown on the inside of the case agrees with what you have ordered 2 2 Condensed Specifications Honeywell recommends that you review and adhere to the operating limits listed in Table 2 1 when you install your controller Table 2 1 Condensed Specifications Specifications Analog Inputs Accuracy 0 25 of full scale typical 1 digit for display Can be field calibrated to 0 05 of full scale typical 16 bit resolution typical Sampling Rate Both inputs are sampled six times per second Temperature Stability 0 01 of Full Scale span C change typical Input Impedance 4 20 Milliampere Input 250 onms 0 10 Volt Input 200K ohms All Others 10 megohms Maximum Lead Wire Resistance Thermocouples 50 ohms leg 100 ohm 200 ohm and 500 ohm RTD 100 ohms leg 100 ohm Low RTD 10 ohms leg Analog Input Signal Failure Operation Burnout Selections Upscale Downscale Failsafe or None Thermocouple Health Good Failing Failure Imminent or Failed Failsafe Output Level Configurable 0 100 of Output range Stray Rejection Common Mode AC 50 or 60 Hz 120 dB with maximum source impedance of 100 ohms or 1 LSB least significant bit whichever is greater with line voltage applied DC 120 dB with
41. displayed AUTOMATIC MODE LAST LSP At power up the controller will use automatic mode with the last local setpoint used before power down displayed 64 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code E E SP Lo 8 0 to 100 of the PV range y 7 March 2012 UDC2500 Universal Digital Controller Product Manual 65 AUTOMATIC MODE LAST RSP At power up the controller will use automatic mode with the last remote setpoint used before power down displayed LAST MODE LAST SETPOINT used before power down LAST MODE LAST LOCAL SETPOINT on power down AMSP 3 4 THREE POSITION CONTROL STEP OUTPUT START UP MODE This selection determines what position the motor will be in when powered up or in the failsafe position 0 LAST OUTPUT At power up in automatic mode the motor position will be the last one prior to power down When the unit goes into FAILSAFE it will stay in automatic mode motor will not be driven to the configured failsafe position 1 FAILSAFE OUTPUT At power up in manual mode the motor will be driven to either the 0 or 100 output position whichever is selected at prompt FAILSAFE For Burnout None when the unit goes into FAILSAFE it will go to manual mode motor will be driven to the configured failsafe position 0 1 AMLS LAST F
42. is diagnostic alarm DISWRN DISABLE WARNING Disables Output Fail message on lower display Configuration 3 15 Display Set Up Group Introduction This group includes selections for Decimal place Units of temperature Language and Power frequency Function Prompts Table 3 16 DISPLY Group Numeric Code 1200 Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code DECMAL NONE DECIMAL POINT LOCATION This ONE selection determines where the decimal point TWO appears in the display NONE No Decimal Place fixed no auto ranging 8888 ONE 1 decimal place 888 8 TWO 2 decimal places 88 88 ATTENTION Auto ranging will occur for selections of one or two decimal places For example should the instrument be configured for two decimal places and the PV exceeds 99 99 then the display will change to a single decimal place so that values of 100 0 and above can be shown TEMPERATURE UNITS This selection will affect the indication and operation DEG F Degrees Fahrenheit Degrees F Annunciator lighted DEG C Degrees Centigrade Degrees C Annunciator lighted NONE No temperature annunciators lighted Upper and Lower Displays will show temperature in Degrees Fahrenheit when inputs are configured for Thermocouple or RTD types March 2012 UDC2500 Universal Digital Controller Product Manual 83 Configuration
43. maximum source impedance of 100 ohms or a 1 LSB whichever is greater with 120 Vdc applied DC to 1 KHz 80 dB with maximum source of impedance of 100 ohms or 1 LSB whichever is greater with 50 Vac applied Normal Mode AC 50 or 60 Hz 60 dB with 100 span peak to peak maximum Digital Inputs Two 30 Vdc source for external dry contacts or isolated solid state contacts Digital Inputs are Optional isolated from line power earth ground analog inputs and all outputs except for the Second Current Output The second Digital Input is mutually exclusive with the Second Current Output 8 UDC2500 Universal Digital Controller Product Manual March 2012 Installation Specifications Controller Output Types Electromechanical Relays One or Two SPDT contacts Both Normally Open and Normally Closed contacts are brought out to the rear terminals Internally socketed Resistive Load 5 amps 120 Vac or 240 Vac or 30 Vdc Inductive Load cos 0 4 3 amps O 130 Vac or 250 Vac Inductive Load L R 7 msec 3 5 amps 30 Vdc Motor 1 6 H P Dual Electromechanical Relays Two SPST contacts One Normally Closed contact for each relay is brought out to the rear terminals Useful for Time Duplex or Three Position Step control applications this option takes the place of one of the above electromechanical relays thus saving it for use as an alarm Units with this output option may have two additional relays
44. naco na cnn cn nncnnncnnos 191 March 2012 UDC2500 Universal Digital Controller Product Manual Introduction 10 MODBUS READ WRITE AND OVERRIDE PARAMETERS PLUS EXCEPTION CODES Ainan ah raia aaraa aie oa aie aake aaas Aaa aria Eaki adaa Aaaa aiie Aakash asa Aaaa a ha SPAS aHa arasa Hada daii aa 192 A A O RN 192 10 2 Reading Control Dita cian a a ee 193 Read Software Options Status cccssccsssestecesseseeecostoneecoceeeesssesteceessesecesteerscoeesseceeseeneceene 194 10 4 Miscellaneous Read Onllys ranir ennen e teededecet i riar i a i 195 10 4 1 Register Addresses for Read OnlyS ooooonoccnoconococonoconaconnconnnonaconnnonnnonn conan cnn nooo coca nccnncnns 195 10 4 2 SetPoint Program Read Only InformatiON ooooccnnncnnonnoonnooncnoncnonono nono noconoconaconncnnccnnccnnos 195 SE MP OMS Aa aii 196 10 6 Using a Computer Setpoint Overriding Controller Setpoint 0 cece eccceesceceeeceeeteceeneeeeeeees 197 107 Contisuration Parameters iii Sie edie eddies bis edt a ee tied 199 10 7 1 RUNNING os ses sate ese scars dees asda sabieues ch ccbdepend dope set vate vassadete vebdincei tbe E 199 10 7 2 SP Ramp Rate Prog rami 260 ccece flee rain RR dia 201 10 7 3 AL CCULUM G2 cosh facies cia 204 10 7 4 Algorta aids aris ein ia aise ee oie ee teeter 205 10 7 5 Output ATEOA Senee e en A A a Reet 206 10 7 6 Input raid soso 207 10 7 7 OPUS AA Na len ere teh ate 210 10 7 8 COMO sa sess ssa ses dots ieee ar E ae EEEE stots sa ESE e
45. priority over the external switch for the RUN HOLD function Reopening the HOLD switch runs the program To go back to the beginning of the program March 2012 March 2012 Monitoring and Operating the Controller Viewing the present ramp or soak segment number and time until you see Viewing the number PA N of cycles left in the Displa program A until you see End Program Disable Program Power outage ATTENTION Upper Display PV value Lower Display XXHH MM Time remaining in the SEGMENT in hours and minutes XX The current number 1 to 12 Upper Display PV value Lower Display REC_XX Number of cycles remaining in the setpoint program X 0 to 99 When the final segment is completed the RUN in the upper display either changes to HOLD if configured for HOLD state or disappears if configured for disable of setpoint programming e The controller either operates at the last setpoint in the program or goes into manual mode failsafe output See Section 3 Configuration Group SPPROGC for details If power is lost during a program upon power up the controller will be in hold and the setpoint value will be the setpoint value prior to the beginning of the setpoint program The program is placed in hold at the beginning The mode will be as configured under PWR UP in the CONTROL group Digital input remote switch operation Prog
46. refer to Tuning Set Up group to set that the selections for PB or GAIN RATE T and MIN or RPM 100 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller 4 8 Control Modes ATTENTION After changing a Local Setpoint value if no other key is pressed it then takes a minimum of thirty 30 seconds elapsed time before the new value is stored in non volatile memory If controller power is removed before this time the new setpoint value is lost and the previous setpoint value is used at power up If after changing the LSP value another key is pressed then the value is stored immediately 4 8 1 Mode Definitions Table 4 7 Control Mode Definitions AUTOMATIC with In automatic local mode the controller operates from the local setpoints and LOCAL automatically adjusts the output to maintain the PV at the desired value SETPOINT In this mode you can adjust the setpoint See Subsection 4 9 Setpoints AUTOMATIC with In automatic remote mode the controller operates from the setpoint measured at the REMOTE remote setpoint input Adjustments are available to ratio this input and add a SETPOINT constant bias before it is applied to the control equation optional See Subsection 3 9 or 3 10 Input 1 or Input 2 MANUAL In the manual mode the operator directly controls the controller output level The optional process variable and the percent output are displayed The configured High and
47. the dimension information in Figure 2 2 2 Orient the case properly and slide it through the panel hole from the front 3 Remove the mounting kit from the shipping container and install the kit as follows e For normal installation two mounting clips are required Insert the prongs of the clips into the two holes in the top and bottom center of the case Figure 2 3 e For water protected installation four mounting clips are required There are two options of where to install the mounting clips 1 Insert the prongs of the clips into the two holes on the left and right side of the top and bottom of the case or 2 on the center on each of the four sides Figure 2 3 e Tighten screws to 2 lb inch 22 Necm to secure the case against the panel CAUTION Over tightening will cause distortion and the unit may not seal properly 4 For water protected installation install four screws with washers into the four recessed areas in the corners of the front bezel Figure 2 3 Push the point of the screw through the center piercing the elastomeric material and then tighten screws to 5 Ib in 56 Necm March 2012 UDC2500 Universal Digital Controller Product Manual 17 Installation 2 6 Wiring 2 6 1 Electrical Considerations Line voltage wiring This controller is considered rack and panel mounted equipment per EN61010 1 Safety Requirements for Electrical Equipment for Measurement Control and Laboratory Use Part 1 General Requirements C
48. the value set Display March 2012 UDC2500 Universal Digital Controller Product Manual 115 Monitoring and Operating the Controller 4 17 Setting Failsafe Mode Introduction You can set the Failsafe Mode to be Latching or Non Latching Set Failsafe Mode Table 4 23 Procedure for Setting a Failsafe Mode A Select Control seta Until you see Set up Group NA Upper Display SET Lower Display CONTRL 2 Select Failsafe Function You will see Function Prompt NA Upper Display LACH Controller goes to manual and output goes to failsafe value NOL Controller mode does not change and output goes to failsafe value Lower Display FSMODE 3 Select a value To select a failsafe mode in the upper display 4 Return to Normal At power up the output will go to the value set Display 4 18 Setpoint Rate Ramp Program Overview Introduction The Setpoint Ramp configuration group lets you enable and configure any of the following e SPRATE a specific rate of change for any local setpoint change Subsection 4 20 e SPRAMP a single setpoint ramp that occurs between the current local setpoint and a final local setpoint over a time interval of 1 to 255 minutes Subsection 4 19 e SPPROG a ramp soak profile in a 12 segment program Subsection 4 21 This section explains the operation of each selection and configuration reference where necessary PV Hot Start This is a standard feature At power up the setpoint is se
49. them to your controller you will now be able to communicate with it via Ethernet March 2012 UDC2500 Universal Digital Controller Product Manual 133 Monitoring and Operating the Controller Configuring the Controller via Ethernet Communications 134 WARNING Configuring the Controller via Ethernet Communications requires that you change your PC s IP settings If you have never done this before then it is strongly recommended that you consult with your Information Technologies IT representative before proceeding First write down the current Local Area Network LAN configuration values for your PC for its IP Address Subnet Mask and Default Gateway settings Put these someplace that you can find them later Connecting to the Ethernet Port in the Controller requires that you have either an Ethernet crossover cable or a MDI compliant Switch or Hub available with a straight through cable The crossover cable can be used to directly connect your PC to the Controller while the Switch or Hub can be used to connect your PC and Controller to the Hub or Switch via straight through cables Once you have made an Ethernet connection between your PC and the controller then change the Local Area Network LAN settings on your PC to be as follows IP Address 10 0 0 3 Subnet Mask 255 255 255 0 Default Gateway 10 0 0 1 Now open your P LE Tool program and select PC Comm Setup and select Ethernet as your Communication Type as shown in Figu
50. to proportional action If the Gain is 2 then the PB is 50 Also defined as HEAT Gain on Duplex models for variations of Heat Cool applications The selection of Proportional Band or Gain is made in the CONTROL parameter group under prompt PBorGAIN RATE T 36 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code Also defined as HEAT Rate on Duplex models for variations of Heat Cool applications 0 02 to 50 00 MIN Reset in Minutes per Repeat 0 02 to 50 00 RPM Reset in Repeats per Minute Integral Time or Reset adjusts the controller s output in accordance with both the size of the deviation SP PV and the time that it lasts The amount of the corrective action depends on the value of Gain The Reset adjustment is measured as how many times proportional action is repeated per minute or how many minutes before one repeat of the proportional action occurs Used with control algorithm PID A or PID B Also defined as HEAT Reset on Duplex models for variations of Heat Cool applications ATTENTION The selection of whether Minutes per Repeat or Repeats per Minute is used is made in the CONTRL parameters group under the prompt MINorRPM 100 to 100 MANUAL RESET is only applicable if you Output use control algorithm PD WITH MANUAL RESET in the Algorit
51. transmitter characterization Scale the 2 input signal to the display value you want for 100 EXAMPLE Process Variable Flow Range of Flow 0 to 250 Liters Minute Actuation Input 2 4 to 20 mA Characterization XMITTER LINEAR Set IN1 HI display value to 250 Set IN1 LO display value to 0 Then 20 mA 250 Liters Minute and 4 mA 0 Liters Minute ATTENTION The control setpoint for Input 2 will be limited by the range of units selected here RATIO ON INPUT 2 Select the Ratio value you want on Input 2 BIAS ON INPUT 2 Bias is used to compensate the input for drift of an input value due to deterioration of a sensor or some other cause Select the bias value you want on Input 2 square root transmitter characterization Scale the 2 input signal to the display value al 999 to 9999 FILTR2 7 0 to 120 seconds 0 No Filter you want for 0 See example above March 2012 UDC2500 Universal Digital Controller Product Manual 61 703 704 705 706 07 FILTER FOR INPUT 2 A software digital filter is provided for Input 1 to smooth the input signal You can configure the first order lag time constant from 1 to 120 seconds If you do not want filtering enter 0 Configuration 3 11 Control Set Up Group Introduction The functions listed in this group deal with how the controller will control the process including Number of Tuning Parameter Sets Setpoint Source Tracking Power up Recall S
52. value selected at Control prompt FAILSAFE March 2012 UDC2500 Universal Digital Controller Product Manual 75 Configuration Function Prompt Selection or Range of Parameter Lower Display Setting Definition Upper Display Numeric Numeric Code Code AUTO TO AUTO AUTOMATIC MODE LAST SP The controller will return to the automatic mode and the last setpoint used before shed SHED SETPOINT RECALL Note If SHEDENAB DISABLE this prompt will not be configurable TO LSP Controller will use last local or remote setpoint used TO CSP When in slave mode the controller will store the last host computer setpoint and use it at the Local setpoint When in monitor mode the controller will shed to the last UDC Local or Remote setpoint used and the LSP is unchanged UNITS PCT PERCENT EGR ENGINEERING UNITS CSRATIO 20 0 to 20 0 COMPUTER SETPOINT RATIO Computer setpoint ratio CSP _BI 999 to 9999 COMPUTER SETPOINT RATIO Computer setpoint ratio in Engineering Units LOOPBK DIS 0 LOCAL LOOPBACK tests the communications ENAB hardware DISABLE Disables the Loopback test ENABLE Allows loopback test The UDC goes into Loopback mode in which it sends and receives its own message The UDC displays PASS or FAIL status in the upper display and LOOPBACK in the lower display while the test is running The UDC will go into manual mode when LOOPBACK is enabled with the output at the Failsafe value The test w
53. which experience load changes or where even a small overshoot beyond the setpoint may result in damage or lost product How it works The fuzzy logic observes the speed and direction of the PV signal as it approaches the setpoint and temporarily modifies the internal controller response action as necessary to avoid an overshoot There is no change to the PID algorithm and the fuzzy logic does not alter the PID tuning parameters This feature can be independently Enabled or Disabled as required by the application to work with TUNE On Demand Accutune II tuning algorithm Configuration To configure this item refer to Section 3 Configuration Set Up Group ATUNE Function Prompt FUZZY Select ENAB enable or DIS disable Use Aor w 4 13 Using Two Sets of Tuning Constants Introduction You can use two sets of tuning constants for single output types and choose the way they are to be switched Does not apply for Duplex control The sets can be e keyboard selected e automatically switched when a predetermined process variable value is reached e automatically switched when a predetermined setpoint value is reached March 2012 UDC2500 Universal Digital Controller Product Manual 111 Monitoring and Operating the Controller Set up Procedure Use the following procedure Table 4 18 to e select two sets e set the switch over value e set tuning constant value for each set Table 4 18 Set U
54. 00 TIMER DIS I MIN or RPM 1 0 PERIOD 0 01 MANRST 1 0 START KEY PB2 or GAIN 2 0 0 L DISP TREM RATE2T 0 00 RESET KEY 12 MIN or 12 RPM 1 0 INCRMT MIN CYCT1 or CT1 20 X3 20 CYC2T2 or CT2 20 OUTALG I OUTALG NOTE 1 X3 20 CRANGE 4 20 SECUR 0 RLY TY MECH LOCK NONE MTR TI 5 AUTOMA ENAB A TUNE ENAB RN HLD ENAB SP SEL ENAB SPRAMP SPRAMP DIS INPUT1 IN1TYP KH TI MIN 3 XMITR1 LIN FINLSP 1000 IN1 HI 2400 SPRATE DIS IN1 LO 0 EUHRUP 0 RATIO1 1 00 EUHRDN 0 BIAS 1 0 0 SPPROG DIS FILTRA 1 BRNOUT UP EMIS 1 0 ATUNE FUZZY DIS INPUT2 IN2TYP 1 5V TUNE TUNE LIN LIN DUPLEX MAN IN2 HI 2400 AT ERR Read Only NONE IN2 LO 0 RATIO2 1 00 BIAS 2 0 0 FILTR2 1 NOTE 1 Model Number Dependent 88 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Group Value or Factory Group Function Value or Factory Prompt Function Prompt Selection Setting Prompt Prompt Selection Setting CONTRL PIDSET ONE ALARMS A1S1TY NONE SW VAL 0 00 A1S1VA 90 LSP S ONE A1S1HL HIGH RSPSRC NONE A1S1EV BEGN SP TRK NONE A1S2TY NONE PWR UP AUTO A1S2VA 90 PWROUT FSAF A1S2HL HIGH SP Hi 2400 A1S2EV BEGN SP Lo 0 A2S1TY NONE ACTION REV A2S1VA 90 OUT Hi 100 A2S1HL HIGH OUT Lo 0 A2S1EV BEGN D BAND 2 0 A2S2TY NONE HYST 0 5 A2S2VA 90 FAILSF 0 0 A2S2HL HIGH FSMODE NOL A2S2EV BEGN PBorGN GAIN ALHYST 0 0 MINRPM MIN ALARM1 NOL BLOCK DIS DIAGAL DIS OPTION AUXOUT DIS DISPLY DECMAL NONE ARANGE 4 20 UNITS F 0
55. 0A2 162 INT R W 0 Last Mode and Last Output 1 Manual Mode Last Output 2 Manual Mode Failsafe Output 3 Automatic Mode 00A3 163 INT R W 0 To Last Local Setpoint used 1 CSP 005A ODA 1 90 161 FP INT R W 20 00 to 20 00 Computer 005B 91 FP R W 999 to 9999 Setpoint Bias 0 Percent 1 Engineering Units UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes 10 7 11 Alarms Table 10 19 lists all the register addresses and ranges or selections for the function parameters in Set up Group Alarms Table 10 19 Set up Group Alarms Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Alarm 1 Setpoint 1 0009 009 FP R W Within the range of Value selected parameter or PV span for deviation alarm Alarm 1 Setpoint 2 OOOA 010 EP R W Within the range of Value selected parameter or PV span for deviation alarm Alarm 2 Setpoint 1 OOOB O11 FP R W Within the range of Value selected parameter or PV span for deviation alarm Alarm 2 Setpoint 2 000C 012 EP R W Within the range of Value selected parameter or PV span for deviation alarm Alarm 1 Setpoint 1 008C 140 INT R W 0 None Type 1 Input 1 2 Input 2 3 PV 4 Deviation 5 Output 6 Alarm on Shed 7 SP Event On 8 SP Eve
56. 1 Setup Group and has three selections e Active Setpoint SP e Process Variable PR Y e Process Variable with no bottom display prompt PR n Exceptions There are three exceptions to the above rules The displays for PID SET Timer and Setpoint Ramp will appear the same as on a dual display model and when displaying Timer or Ramp values the default display switchover feature is disabled Auto only Mode The single display model is Auto only mode The Auto Manual key has no effect on controller mode As a result of this the failsafe mode is always non latching While a failsafe condition exists the controller output will assume the failsafe value When the failsafe condition goes away normal automatic operation continues 98 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Single Display Parameters Table 4 5 Single Display Parameters Lower Display Prompt Upper Display Value blank Process Variable Default selection PV Process Variable Default selection SP Local Setpoint 1 Default selection 2SP Local Setpoint 2 Default selection RSP Remote Setpoint Default selection OUT Output DEV Deviation 2IN Input 2 AUX Aux Output value BIA PD MR bias value PIDS x Process Variable Active PID set RP xxxM Process Variable SP Ramp time left HH MM or MM SS Process Variable Timer display March 2012 UDC2500 Universal Digita
57. 10 Volts March 2012 UDC2500 Universal Digital Controller Product Manual 143 Input Calibration 0 to 10 Volts Refer to Figure 5 6 and wire the controller according to the procedure given in Table 3 8 Table 5 8 Set Up Wiring Procedure for 0 to 10 Volts 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 6 2 Place voltage source at zero before switching on 3 Do not switch voltage source ON OFF while connected to the instrument 2 Test RO 26 TES ER 27 Volt Source O Figure 5 6 Wiring Connections for 0 to 10 Volts Milliamperes Refer to Figure 5 5 and wire the controller according to the procedure given in Table 3 7 Table 5 9 Set Up Wiring Procedure for Milliampere Inputs 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 7 2 Place current source at zero before switching on 3 Do not switch current source ON OFF while connected to the instrument Milliampere Source Figure 5 7 Wiring Connections for 0 to 20 mA or 4 to 20 mA Inputs 144 UDC2500 Universal Digital Controller Product Manual March 2012 Input Calibration 5 5 Input 1 Calibration Procedure Preliminary Steps e Apply power and allow the controller to warm up for 30 minutes before you calibrate e Please read Subsection 5 4 Input I Set Up Wiring before beginning the procedure e Make sure you have LOCK set to NONE See Su
58. 136 140 141 142 142 143 144 144 147 148 154 156 180 194 March 2012 Introduction 1 Introduction 1 1 Overview Function The UDC2500 is a microprocessor based stand alone controller It combines a high degree of functionality and operating simplicity in a 1 4 DIN size controller This instrument is an ideal controller for regulating temperature and other process variables in numerous heating and cooling applications as well as in metal working food pharmaceuticals semiconductor testing and environmental work The UDC2500 monitors and controls temperatures and other variables in applications such as environmental chambers plastic processing machines furnaces and ovens and packaging machinery Features 90 250 Vac or 24 Vac dc Power Supply Input Output Isolation Isolated Auxiliary Current Output Digital Inputs Modbus RS 485 Infrared or Ethernet TCP IP Communications Infrared interface Timer Accutune III Tuning with Fuzzy Logic Overshoot Suppression 2nd Input Remote Setpoint Setpoint Ramp Rate Program Three Position Step Control Duplex Heat Cool Easy to Read Displays The dedicated vacuum fluorescent displays with multi language prompts make the operator interface easy to read understand and operate Programmed sequences of displays assure quick and accurate entry of all configurable parameters Easy to Operate Simple keystrokes let you select input and range configuration set the op
59. 1816 0 100 mV 13 769 mV E 454 to 1832 270 to 1000 9 835 mV 76 373 mV E low 200 to 1100 129 to 593 6 472 mV 44 455 mV J 0 to 1600 18 to 871 0 886 mV 50 060 mV J med 20 to 900 7 to 482 0 334 mV 26 400 mV J low 20 to 550 7 to 288 0 334 mV 15 650 mV K 0 to 2400 18 to 1816 0 692 mV 52 952 mV K med 20 to 1200 29 to 649 1 114 mV 26 978 mV K low 20 to 750 29 to 399 1 114 mV 16 350 mV NiMo NiCo NM90 32 to 2500 0 to1371 0 000 mV 71 773 mV NM90 low 32 to 1260 0 to 682 0 000 mV 31 825 mV Nicrosil Nisil Nic 0 to 2372 18 to1300 0 461 mV 47 513 mV Nic low 0 to 1472 18 to 800 0 461 mV 28 455 mV R 0 to 3100 18 to1704 0 090 mV 20 281 mV 138 UDC2500 Universal Digital Controller Product Manual March 2012 Input Calibration Sensor Type PV Input Range Range Values S O to 3100 18 to1704 0 092 mV 17 998 mV T 300 to 700 184 to 371 5 341 mV 19 097 mV T low 200 to 500 129 to 260 4 149 mV 12 574 mV W5W26 0 to 4200 18 to 2315 0 234 mV 37 075 mV W5W26 low 0 to 2240 18 to 1227 0 234 mV 22 283 mV RP20 RP40 32 to 3216 0 to1880 0 000 mV 4 933 mV Thermocouple 50 to 150 46 to 66 1 54 mV 4 62 mV Differential Honeywell Radiamatic Type RH 0 to 3400 18 to 1871 0 00 mV 57 12 mV Type RI 0 to 3400 18 to 1871 0 00 mV 60 08 mV RTD Alpha 0 00385 per IEC 60751 1995 100 ohms 300 to 1200 184 10649 25 202 ohms 329 289 ohms 100 ohms low 300 to 300
60. 2 Contact closure allows Output to track Input 2 While the switch is open the output is in accordance with its pre defined functionality When the switch is closed the output value in percent will track the Input 2 percent of range value When the switch is reopened the output will start at this last output value and normal PID action will then take over control The transfer is bumpless PV HOTSTART Contact closure starts the SP Ramp or SP Program at the original selected starting Setpoint Value that existed at the time that the SP Ramp or Program was first started Opening contact has no effect This configuration must be selected prior to the first time the SP Ramp or Program is placed in the RUN mode as otherwise the unit will not be able to capture the initial Setpoint value This selection allows the unit to retain the initial Setpoint value even if power to the unit is lost When the STATE selection in the SP Ramp or Program Set Up group is set to HOLD and the digital input contact is left closed then when the end of the program or ramp is reached the program or ramp will 72 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code automatically restart at the initial Setpoint value If power to the unit is lost while while a SP Ramp or Program was running then if th
61. 3 5 SPRAMP Group Numeric Code 200 Function Prompts Table 3 6 ATUNE Group Numeric Code 300 Function Prompts Table 3 7 ALGOR Group Numeric Code 400 Function Prompts Table 3 8 OUTPUT Group Numeric Code 500 Function Prompts Table 3 9 INPUT 1 Group Numeric Code 600 Function Prompts Table 3 10 Table 3 11 Table 3 13 Table 3 14 Table 3 15 Table 3 16 INPUT2 Group Numeric Code 700 Function Prompts Table 3 12 CONTRL Group Numeric Code 800 Function Prompts OPTION Group Numeric Code 900 Function Prompts Communications Group Numeric Code 1000 Function Prompts ALARMS Group Numeric Code 1100 Function Prompts DISPLY Group Numeric Code 1200 Function Prompts Table 4 1 Procedure to Enter a Security Code Table 4 2 Annunciators Table 4 3 Lower Display Key Parameter Prompts Table 4 4 Diagnostic Messages Table 4 5 Single Display Parameters Table 4 6 Procedure for Starting Up the Controller Table 4 7 Control Mode Definitions Table 4 8 Changing Control Modes Dual Display Only Table 4 9 Procedure for Changing the Local Setpoints Table 4 10 Table 4 11 Table 4 12 Table 4 13 Table 4 14 Table 4 15 Table 4 16 Table 4 17 Table 4 18 Table 4 19 Table 4 20 Table 4 21 Table 4 22 Table 4 23 Table 4 24 Table 4 25 March 2012 Procedure for Switching Between Setpoints Procedure for Starting TUNE Procedure for Using AUTOMATIC TUNE at Start up for Duplex Control Procedure for Using BLENDED TUNE at Start up for Duple
62. A equation the controller gives only an integral response to a setpoint change with no effect on the output due to the gain or rate action and it gives full response to PV changes Otherwise controller action is as described for the PID A equation See note on PID A PIDA 1 PIDB 2 48 UDC2500 Universal Digital Controller Product Manual March 2012 Function Prompt Selection or Range of Setting Lower Display Upper Display Numeric Numeric Code Code PDMR TPSC 4 Configuration Parameter Definition PD WITH MANUAL RESET is used whenever integral action is not wanted for automatic control The equation is computed with no integral contribution The MANUAL RESET which is operator adjustable is then added to the present output to form the controller output Switching between manual and automatic mode will be bumpless If you select PD with Manual Reset you can also configure the following variations e PD Two Mode control e P Single Mode control e Set Rate D to 0 ATTENTION Other prompts affected MANRST in the Tuning Set Up group THREE POSITION STEP CONTROL TPSC The Three Position Step Control algorithm allows the control of a valve or other actuator with an electric motor driven by two controller relay outputs one to move the motor upscale the other downscale without a feedback slidewire linked to the motor shaft The deadband is adjustable in the same manner as the duplex output algor
63. Check the relay output Put the controller into Manual mode Vary the output above and below the present value Observe OUT1 indicator on the operator interface Listen for a click from the relay when the OUT1 indicator changes state 4 Check the Current Proportional Put the controller into Manual mode and change Output 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 Section 6 Output Calibration for details 6 Change relay and or Current Output Installation instructions supplied with new board boards UDC2500 Universal Digital Controller Product Manual March 2012 Procedure 6 Troubleshooting Service Table 7 10 explains how to troubleshoot Alarm Relay Output failure Table 7 10 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 Check that the applicable alarm relay actuates properly depending on what you have set at prompt AxSxTYPE If it does check the field wiring Check the contacts Change the relay and or the current output board Change MCU board Reconfigure if necessary Refer to Section 3 Configuration for details 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 t
64. Communications User Manual 51 55 25 66 March 2012 UDC2500 Universal Digital Controller Product Manual 183 Modbus RTU Function Codes Register Address Structure Table 9 1 Integer Parameter Type Register Numbers Dec Type 1 NOT SUPPORTED 16 bit Unsigned Integer 2 Attribute NOT SUPPORTED 1 Read Only 2 Read Write Value 16 bit integer Read Write AAA 4 NotUsed NOTSUPPORTED Low Range 16 bit integer NOT SUPPORTED 3 3 6 NotUsed NOTSUPPORTED 7 High Range 16 bit Integer NOT SUPPORTED 8 NotUsed SC NOTSUPPORTED 9to13 Description Text ASCII string NOT SUPPORTED Table 9 2 Floating Point Parameter Type Register Numbers Dec Type 2 NOT SUPPORTED Type 2 NOT SUPPORTED IEEE Floating Point Attribute NOT SUPPORTED 1 Read Only 2 Read Write Value float high word Read Write pO Low Range float high word NOT SUPPORTED __ Low Range float low word NOT SUPPORTED __ High Range float high word NOT SUPPORTED _______ High Range float low word NOT SUPPORTED __ IO Value float low word NOT SUPPORTED 9 to 13 Description Text ASCII string NOT SUPPORTED Register Count The register count depends on the data format of the registers being read or written Integer data is represented in sixteen bits and is transferred high byte first Floating point data is transferred in IEEE 32 bit format The regis
65. Digital Controller Product Manual 15 Installation 2 5 Mounting Physical Considerations The controller can be mounted on either a vertical or tilted panel using the mounting kit supplied Adequate access space must be available at the back of the panel for installation and servicing activities e Overall dimensions and panel cutout requirements for mounting the controller are shown in Figure 2 2 e The controller s mounting enclosure must be grounded according to CSA standard C22 2 No 0 4 or Factory Mutual Class No 3820 paragraph 6 1 5 e The front panel is moisture rated NEMA3 and IP55 rated and can be easily upgraded to NEMA4X and IP66 Overall Dimensions Max panel thickness me 19 1 x inches 1S 0 35 108 6 92 0 0 8 4 28 0 00 Panel 3 62 0 03 Cui n 0 00 lt gt 92 0 A 113 1 0 4 45 3 62 0 03 17 9 0 00 0 70 Figure 2 2 Mounting Dimensions not to scale 16 UDC2500 Universal Digital Controller Product Manual March 2012 Installation Mounting Method Before mounting the controller refer to the nameplate on the outside of the case and make a note of the model number It will help later when selecting the proper wiring configuration nal Mounting clips O Attach screws and washers here for water protection Mi Funcion 2 Figure 2 3 Mounting Methods Mounting Procedure Table 2 4 Mounting Procedure 1 Mark and cut out the controller hole in the panel according to
66. E Tool to be per the controller s new IP Address You will also need to re configure the Local Area Network LAN settings on your PC back to their original settings On some PCs and LANs it is possible to simply allow the PC to get these settings automatically via the DHCP server Contact your Information Technologies IT representative to see 1f this is available on your PC 136 UDC2500 Universal Digital Controller Product Manual March 2012 Input Calibration 5 Input Calibration A WARNING SHOCK HAZARD INPUT CALIBRATION 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 CALIBRATION 5 1 Overview Introduction This section describes the field calibration procedures for Input 1 and Input 2 e All input actuations in every UDC2500 controller are fully factory calibrated and are ready for configuration by the user e Field Calibration can improve the accuracy of the Controller if necessary for a particular application CAUTION The field calibration will be lost if a change in input type configuration is implemented at a later time The original factory calibration data remains available for later use after a field calibration is done See subsection 0 if you want to restore factory calibration values What s in this section The following topics are covered in this section 5 1 Overview 137 5 2
67. FOR EXAMPLE If input 1 is a 4 to 20 mA signal but the signal represents a type K H thermocouple then configure K H and the controller will characterize the 4 to 20 mA signal so that it is treated as a type K thermocouple input high range OONDOARWN O Parameter definitions are the same as in IN1 TYPE 999 to 9999 INPUT 1 HIGH RANGE VALUE in l engineering units is displayed for all inputs but can only be configured for linear or square root transmitter characterization floating in engineering units Scale the 1 input signal to the display value you want for 100 EXAMPLE Process Variable Flow Range of Flow 0 to 250 Liters Minute Actuation Input 1 4 to 20 mA Characterization XMITTER LINEAR Set IN1 HI display value to 250 Set IN1 LO display value to O Then 20 mA 250 Liters Minute and 4 mA 0 Liters Minute ATTENTION The control setpoint will be limited by the range of units selected here March 2012 UDC2500 Universal Digital Controller Product Manual 57 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code INPUT 1 LOW RANGE VALUE in engineering units is displayed for all inputs IN1 LO 999 to 9999 floating in but can only be configured for linear or square root transmitter characterization Scale the 1 input signal to the display value you want for 0 See example above engineeri
68. Honeywell UDC2500 Universal Digital Controller Product Manual 51 52 25 127 Revision 6 March 2012 Honeywell Process Solutions Notices and Trademarks Copyright 2007 by Honeywell Revision 6 March 2012 While this information is presented in good faith and believed to be accurate Honeywell disclaims the implied warranties of merchantability and fitness for a particular purpose and makes no express warranties except as may be stated in its written agreement with and for its customers In no event is Honeywell liable to anyone for any indirect special or consequential damages The information and specifications in this document are subject to change without notice Honeywell PlantScape Experion PKS and TotalPlant are registered trademarks of Honeywell International Inc Other brand or product names are trademarks of their respective owners Honeywell Process Solutions 1860 West Rose Garden Lane Phoenix Arizona 85027 UDC2500 Universal Digital Controller Product Manual March 2012 About This Document Abstract This document provides descriptions and procedures for the Installation Configuration Operation and Troubleshooting of your UDC2500 Controller Revision Information Document Name Document ID Revision Publication Date UDC2500 Universal Digital Controller number Product Manual Rating Operating Altitude added 51 52 25 127 6 March 2012 References The following list identifies a
69. Maintenance Data Menu Figure 4 6 Loop Data Maintenance Screen Figure 4 7 Alarm Details Maintenance Screen Figure 4 8 Digital Input Details Screen Figure 4 9 Status Data Maintenance Screen Figure 4 10 Ethernet Status Maintenance Screen Figure 4 11 IR Communications Address Figure 4 12 Online Configuration Figure 4 13 Configuration Upload in Progress Figure 4 14 Ethernet Communications Type Selection Figure 4 15 Ethernet Communications Address Figure 4 16 Configuration Upload in Progress Figure 5 1 Input 1 and Input 2 Wiring Terminals Figure 5 2 Wiring Connections for Thermocouple Inputs Using an Ice Bath Figure 5 3 Wiring Connections for Thermocouple Inputs Using Thermocouple Source Figure 5 4 Wiring Connections for RTD Resistance Thermometer Device Figure 5 5 Wiring Connections for Radiamatic T C Differential Millivolts or Volts Figure 5 6 Wiring Connections for 0 to 10 Volts Figure 5 7 Wiring Connections for O to 20 mA or 4 to 20 mA Inputs Figure 5 8 Wiring Connections for 0 to 20 mA or 4 to 20 mA Input Input 2 Figure 5 9 Wiring Connections for 0 to 2 Volts 0 to 5 Volts or 1 to 5 Volts Input Input 2 Figure 6 1 Wiring Connections for Calibrating Current Output Figure 6 2 Wiring Connections for Calibrating Auxiliary Output Figure 8 1 UDC2500 Exploded View Figure 10 1 Software Option Status Information xiv UDC2500 Universal Digital Controller Product Manual 126 127 128 129 130 131 132 133 133 134 135
70. Manual March 2012 Input Calibration Procedure The calibration procedure for Input 2 is listed in Table 5 13 The numeric codes are also listed Table 5 13 Input 2 Calibration Procedure Numeric Code 20000 sew operation Pess ea 1 Enter Calibration a Upper Display CAL Mode o Lower Display INPUT2 20000 until you see 97 N Youwill see Upper Display DIS 0 Lower Display CALIN2 20001 J An or You will see Upper Display BEGN 1 Lower Display CALIN2 20001 2 Calibrate 0 You will see Upper Display APLY 2 Lower Display IN2ZRO 20002 e Adjust your calibration device to an output signal equal to the 0 range value for your particular input sensor J e Wait 15 seconds then go to the next step 3 Calibrate 100 You will see Upper Display APLY 2 Lower Display IN2SPN 20003 9 NS e Adjust your calibration device to an output signal equal to the 100 range value for your particular input sensor e Wait 15 seconds then go to the next step 4 Exit the Function The controller stores the calibration constants Calibration Mode Na To store the calibration constants and exit the calibration mode March 2012 UDC2500 Universal Digital Controller Product Manual 149 Input Calibration 5 8 Restore Input Factory Calibration Introduction The factory calibration constants for all the input actuation types that can be used with the contro
71. Overview essssseessresesesstsresrtssesrisstestsseestestesestesserrteseesteses 116 AAO Setpoint Ramp iii ia a ries 117 4 20 S tpomtRiteiipndotoiimdlul told eiii 118 4 21 Setpoint Ramp Soak Programming ooooococononcnonononoconnnonnconnnono nana nonanonn nono n conan nn ancora nn nncnn cnn nannnannss 119 4 22 PLE Tool Maintenance Screens eri iesiti torien e i iiaii e oii aad as 126 4 23 Configuring your Ethernet Connection seeeesseereeseeresresresresrtsstsrtssetstssressestessestessesresseesteses 132 viii UDC2500 Universal Digital Controller Product Manual March 2012 5 5 1 5 2 5 3 5 4 5 5 5 6 5 7 5 8 6 1 6 2 6 3 6 4 7 1 7 2 7 3 7 4 7 5 7 6 17 7 8 7 9 8 1 8 2 9 1 9 2 9 3 9 4 Introduction INPUT CALIBRATI ON c iii 137 OVA AA A ta tt Na 137 Minimum and Maximum Range Values oooconnccnnconiconocnnooncnoncnononononononnoconocnnncnnncnnc cnn crac cra nono 138 Preliminary Information cdas oia 140 Input Set Up WINS tt Na le o 141 Input 1 Calibration Procedure es 15 i22 diss eetitazbistin csi theses tin els EEE eiii apli 145 Input 2 SetUp WiN Eteen teree Ea daje dai 147 Input 2 Calibration Procedure alii iin A AE aE A E EEA aa 148 Restore Input Factory Calibrations n a E a a a 150 OUTPUT GALIBRATION ollo AA Edad 153 OVCIVI Wii rana 153 Current Output Calibration tii did 154 Auxiliary Output Calibration ists stsivin nhs rss iii tira 156 Restore Output Factory Calibration Procedure
72. P 2 must be in use March 2012 UDC2500 Universal Digital Controller Product Manual 45 Configuration Function Prompt Selection or Range of Setting Lower Display Upper Display Parameter Definition Numeric Numeric Code Code DIS DISABLE The current SetPoint is used to derive a single set of blended tuning parameters This tuning is performed over the range of the output limits similar to Simplex Tuning The Tuning Parameters derived are placed into both the HEAT and COOL tune sets PID 1 and PID 2 AT ERR 304 Read Only NONE 0 RUN 5 ABRT 4 SP2 6 ACCUTUNE ERROR STATUS When an error is detected in the Accutune process an error prompt will appear NONE No errors occurred during last Accutune procedure RUNNING An Accutune process is still active checking process gain even though TUNE is not lit It does not affect keyboard operation CURRENT ACCUTUNE PROCESS ABORTED Caused by one of the following conditions changing to manual mode e digital input detected e in heat region of output but a cool output was calculated or vice versa SP2 LSP2 not configured or a Setpoint other than LSP1 or LSP2 is in use 46 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration 3 7 Algorithm Set Up Group Introduction This data deals with various algorithms in the controller and Timer functions The Timer section allows you to configure a
73. Proportional Output Failure Step What to do How to do it 1 Make sure the controller is configured Make Output Algorithm Set Up group function for Time Proportional output prompt OUTALG RLY or RLYD Refer to Section 3 Configuration 2 Check the field wiring Make sure the NO or NC contact wiring is correct Refer to Section 2 Installation for details 3 Check the output Put the controller into Manual mode Vary the output above and below the present value Observe OUT1 indicator on the operator interface Contact should change state 0 open 100 closed Listen for a click from the relay when the OUT1 indicator changes state 4 Check relay Change relay 5 Change MCU board Installation instructions supplied with the new board March 2012 UDC2500 Universal Digital Controller Product Manual 171 Troubleshooting Service Procedure 5 172 Table 7 9 explains how to troubleshoot Current Time or Time Current Proportional Output failure Table 7 9 Troubleshooting Current Time or Time Current Proportional Output Failure Step What to do How to do it 1 Make sure the controller is configured Make Output Algorithm Set Up group function for Time Current or Current Time prompt OUT ALG TCUR or CURT Proportional output i Refer to Section 3 Configuration 2 Check the field wiring Make sure the NO or NC contact wiring selection is correct Refer to Section 2 Installation for details 3
74. RUNNING The Accutune process is still active Read Only NONE NO ERRORS OCCURRED None DURING LAST ACCUTUNE PROCEDURE IDFL PROCESS IDENTIFICATION e Illegal Values FAILURE try Accutune again Autotuna has abone e untunable process contact local application because an illegal value of engineer GAIN RATE or reset was calculated ABRT CURRENT ACCUTUNE Try Accutune again PROCESS ABORTED caused by the following conditions a Operator changed to Manual mode b Digital Input detected c In Heat region of output and a Cool output calculated or vice versa SP2 LSP2 not enabled or LSP1 or Enable LSP2 and configure the desired LSP1 and LSP2 not in use only applies LSP2 setpoints to Duplex Tuning Aborting Accutune To abort Accutune and return to the last previous operation SP or output level press M A RESET key to abort the Accutune process 110 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Completing Accutune When Accutune is complete the calculated tuning parameters are stored in their proper memory location and can be viewed in the TUNING Set up Group and the controller will control at the local setpoint using these newly calculated tuning constants 4 12 Fuzzy Overshoot Suppression Introduction Fuzzy Overshoot Suppression minimizes Process Variable overshoot following a setpoint change or a process disturbance This is especially useful in processes
75. SAF 0 to 100 of the PV range SETPOINT HIGH LIMIT T his selection prevents the local and remote setpoints from going above the value selected here The setting must be equal or less than the upper range of the PV 807 808 09 SET POINT LOW LIMIT T his selection prevents the local and remote setpoints from going below the value selected here The setting must be equal or greater than the lower range of the PV CONTROL OUTPUT DIRECTION Select direct or reverse output action DIRECT ACTING CONTROL The controller s output increases as the process variable increases REVERSE ACTING CONTROL The controller s output decreases as the process variable increases Configuration Function Prompt Lower Display Numeric Code OUT Hi 0 to 100 5 to 105 0 to 100 5 to 105 5 0 to 25 0 0 0 to 25 0 0 5 to 5 0 0 0 to 100 0 of PV FAILSF 0 to 100 FAILSF 0 100 66 UDC2500 Universal Digital Controller Product Manual Selection or Range of Setting Upper Display Numeric Code Parameter Definition HIGH OUTPUT LIMIT T his is the highest value of output beyond which you do not want the controller automatic output to exceed For relay output types For current output types LOW OUTPUT LIMIT T his is the lowest value of output below which you do not want the controller automatic output to exceed For relay output types For current output types DEADBAND i
76. SE EE e SE 212 10 7 9 0110 1 REE E EE E ET EEE EEE EE E E E 214 10 710 CoMMUNICA OS its E e e a 216 VOTALO E anh oe aa oid ene a aa 217 107 12 lt DiSpPlaYciund dl ara a ete ae 220 Modbus RTU Exception Codes c 22ccciesgecs a asiste le 221 14 ETHERNET TOP P ascii ii ica 223 OVERVIE Wisin enana E ee E Ea N ea e EEEa asa 223 12 FURTHER INFORMATION c cioicciniciccnancc ncniacioncnnnaninananinanencnsnincnancni dando ein n anda 224 Modbus RTU Serial Communications 0 0 cee eeeeseceseceseceseceseesseeeseeseaeeeseeeaeeeaaecaaecsaeceaeenaeen 224 12 2 Modbus Messaging on TCP IP eee cssecssecssecsseceseceseesseeeseeeeseeeseecseecsaecsecsaeceaeenseeseeeeneeeees 224 How to Apply Digital Instrumentation in Severe Electrical Noise Environments 224 1 DIE 225 O O 228 UDC2500 Universal Digital Controller Product Manual March 2012 Tables Table 2 1 Condensed Specifications Table 2 2 Control Relay Contact Information Table 2 3 Alarm Relay Contact Information Table 2 4 Mounting Procedure Table 2 5 Permissible Wiring Bundling Table 2 6 Universal Output Functionality and Restrictions Table 2 7 Terminals for connecting a UDC to a MDI Compliant Hub or Switch Table 2 8 Terminals for connecting a UDC directly to a PC utilizing a straight through cable Table 3 1 Configuration Topics Table 3 2 Configuration Prompt Hierarchy Table 3 3 Configuration Procedure Table 3 4 TUNING Group Numeric Code 100 Function Prompts Table
77. STORE Lower 5 Press the 4 key The instrument will now display CFG Upper RESTORE Lower 6 Press the FUNCTION Key The instrument will now display DOIN RESTORE 7 When the instrument finishes the restore operation it automatically resets itself and restarts in the product mode The instrument configuration will now be the same as it was when the instrument left the factory and all user entered configurations since that time have been overwritten March 2012 UDC2500 Universal Digital Controller Product Manual 177 Troubleshooting Service 7 9 Software Upgrades Introduction This procedure enables software features that were not ordered from the factory See Table 8 3 for a list of the available Software Upgrades ATTENTION This procedure cannot be undone it is a one way process Each instrument has a unique code number sequence so the following procedure must be performed on each instrument to be upgraded Table 7 16 explains how to enable new software features Table 7 16 Software Upgrades Step What to do 1 Turn off the power to the instrument for at least five seconds 2 Turn the power back on and simultaneously press the FUNCTION and 4 keys This must be done while TEST DONE is being displayed 3 If step 2 was performed correctly the instrument will now display UDC Upper UPDATE Lower 4 Press the FUNCTION Key The instrument will now disp
78. TUNE Group Numeric Code 300 Function Prompts Function Prompt Selection or Range of Setting Lower Display Upper Display Numeric Code FUZZY DUPLEX 303 MANU AUTO Numeric Code Parameter Definition FUZZY OVERSHOOT SUPPRESSION Can be enabled or disabled independently of whether Demand Tuning or SP Tuning is enabled or disabled DISABLE Disables Fuzzy Overshoot Suppression ENABLE The UDC uses Fuzzy Logic to suppress or minimize any overshoot that may occur when PV approaches SP It will not recalculate any new tuning parameters ACCUTUNE lll DISABLE Disables the Accutune function DEMAND TUNING If TUNE is selected and tuning is initiated through the operator interface or digital input if configured the algorithm calculates new tuning parameters and enters them into the tuning group This tuning requires no process knowledge and does not require line out for initialization DUPLEX ACCUTUNING lll These prompts only appear when a duplex output type has been configured MANUAL Tune manually using LSP 1 and LSP 2 values LSP 1 is used to derive tuning parameters associated with HEAT output gt 50 LSP 2 is used to derive tuning parameters associated with COOL output lt 50 AUTOMATIC Tuning is performed automatically on both HEAT and COOL sequentially LSP 1 is used for HEAT tuning and LSP 2 is used for COOL tuning To initiate tuning either LSP 1 or LS
79. UDC2500 Universal Digital Controller Product Manual March 2012 Modbus RTU Function Codes 9 4 1 Write Configuration Examples Example 1 The following is an example of a request to write the Gain 1 value using Function code 21 15 Hex Request Message Write Gain 1 1 5 ID Tag 1 02 15 OB 06 00 03 00 01 00 02 3F CO 00 00 CRC16 Where 02 Address 15 Function Code 21 15 Hex OB Byte Count 06 Reference Type IEEE Floating Point 00 03 File Number Access Data Value 00 01 Register Address Standard Access Gain 1 ID Tag 1 00 02 Register Count Floating Point Data 3FC00000 1 50 CRC16 This is the response to the above request Response Message The response is an echo of the request 02 15 OB 06 00 01 00 02 00 02 3F CO 00 00 CRC 16 March 2012 UDC2500 Universal Digital Controller Product Manual 191 Modbus Read Write and Override Parameters plus Exception Codes 10 Modbus Read Write and Override Parameters plus Exception Codes 10 1 Overview Introduction This section contains information concerning Reading Writing and Overriding parameters in this instrument There are two types of parameters e Data Transfer These parameters include reading control data option status and reading or changing setpoints e Configuration Data All the configuration data is listed in the order in which it appears in the controller Each type of parameter has the identifying codes listed with it What s
80. UXILIARY OUTPUT INPUT 1 If necessary install a zener diode here to reduce voltage at the transmitter A 1N4733 will reduce the voltage at the transmitter to approximately 25 Vdc Figure 2 19 Transmitter Power for 4 20 mA 2 Wire Transmitter Using Auxiliary Output UDC2500 Universal Digital Controller Product Manual March 2012 Configuration 3 Configuration 3 1 Overview Introduction Configuration is a dedicated operation where you use straightforward keystroke sequences to select and establish configure pertinent control data best suited for your application To assist you in the configuration process there are prompts that appear in the upper and lower displays These prompts let you know what group of configuration data Set Up prompts you are working with and also the specific parameters Function prompts associated with each group Table 3 1 shows an overview of the prompt hierarchy as it appears in the controller What s in this section The following topics are covered in this section Table 3 1 Configuration Topics 38 Output Ser Up Group 3 9 ImputISetUpGroup_ O 6 O 3 10 Input2SetUpGroup o 3 12 Options Set Up Group March 2012 UDC2500 Universal Digital Controller Product Manual 33 Configuration 3 2 Configuration Prompt Hierarchy Set Up Group Table 3 2 Configuration Prompt Hierarchy a or CT2 X3 Function Prompts a Since eo GAIN GAIN 2 or x 1 to 12 Program conclud
81. Until you see Set up Group NA Upper Display the PV value Lower Display PIDSX X 1 or 2 2 Mw To change PID SET 1 to PID SET2 or Vice Versa You can use Accutune on each set 3 P N To accept changes En 4 14 Alarm Setpoints Introduction An alarm consists of a relay contact and an operator interface indication The alarm relay is de energized if setpoint 1 or setpoint 2 is exceeded The alarm relay is energized when the monitored value goes into the allowed region by more than the hysteresis The relay contacts can be wired for normally open NO energized or normally closed NC de energized using internal jumper placement See Table 2 3 in the Section 2 Installation for alarm relay contact information There are four alarm setpoints two for each alarm The type and state High or Low is selected during configuration See Subsection 3 13 Configuration for details Alarm Setpoints Display Table 4 20 Procedure for Displaying Alarm Setpoints step Operation Press mese 1 Select Alarm setup Until you see Set up Group NA Upper Display SET Lower Display ALARMS 2 Access the Alarm Function To successively display the alarm setpoints and their values Setpoint Values NA Their order of appearance is shown below Upper Display the alarm setpoint value Range values are within the range of the selected parameters except DEVIATION DE value PV Span EVENTS E ON E OF value Event Segment Number
82. Vac dc Power Inrush Current 10A maximum for 4 ms under operating conditions reducing to a maximum of 225 mA 90 to 250 Vac operation or 750 mA 24 Vac dc operation after one second CAUTION When applying power to more than one instrument make sure that sufficient power is supplied Otherwise the instruments may not start up normally due to voltage drop from the inrush current Weight 3 lbs 1 3 kg 10 UDC2500 Universal Digital Controller Product Manual March 2012 Installation Environmental and Operating Conditions Parameter Reference Rated Operative Transportation and Limits Storage Ambient Temperature 25 3 C 15 to 55 C 0 to 55 C 40 to 66 C 7745 F 58 to 131 F 32 to 131 F 40 to 151 F Relative Humidity 10 to 55 10 to 90 5 to 90 5 to 95 Vibration Frequency Hz 0 0 to 70 0 to 200 0 to 200 Acceleration g 0 0 4 0 6 0 5 Mechanical Shock Acceleration g 0 1 5 20 Duration ms 0 30 30 30 Line Voltage Vdc 24 1 22 to 27 20 to 27 Line Voltage Vac 90 to 240 Vac 120 1 90 to 240 90 to 250 240 2 24 Vac 24 11 20 to 27 20 to 27 Frequency Hz 50 0 2 49 to 51 48 to 52 For Vac 60 0 2 59 to 61 58 to 62 The maximum moisture rating only applies up to 40 C 104 F For higher temperatures the RH specification is derated to maintain constant moisture content March 2012 UDC2500 Universal Digit
83. a value within the Cool Zone output below 50 Until the A indicator is lighted on controllers with Manual option Until NoTUNE is shown on lower display Select DoSLOW or DoFAST in lower display Upper display will flash TUNE as long as ACCUTUNE process is operating When process completes tuning parameters are calculated and lower display will show NoTune prompt 4 11 4 Using BLENDED TUNE at start up for Duplex Heat Cool When DUPLEX has been configured for DISABLE This is the preferred selection for Heat Cool applications which use a highly insulated chamber a chamber which will lose heat very slowly unless a cooling device is applied Only one local setpoint LSP 1 is needed for this selection March 2012 UDC2500 Universal Digital Controller Product Manual 107 Monitoring and Operating the Controller This selection results in performance tuning over the full range utilizing both Heat and Cool outputs to acquire blended tune values that are then applied to both Heat and Cool tuning parameters Both PID sets are set to the same values Table 4 13 Procedure for Using BLENDED TUNE at Start up for Duplex Control sep Operation press mesa 1 Configure LSP1 2 3 Switch to Automatic Mode 4 Show Tuning Prompt 5 Initiate Tuning 6 Tuning in operation Until SP Local Setpoint 1 shows in the lower display Until the Setpoint is to the desired value U
84. ability DC2500 DC2501 y pecify Control Output and or Alarms None Can be used as an indicator only Current Output 4 to 20ma 0 to 20 ma Electro Mechanical Relay 5 Amp Form C Solid State Relay 1 Amp Open Collector transistor output Dual 2 Amp Relays Both are Form A Heat Cool Applications No Additional Outputs or Alarms One Alarm Relay Only E M Relay 5 Amp Form C Plus Alarm 1 5 Amp Form C Relay Solid State Relay 1 Amp Plus Alarm 1 5 Amp Form C Relay Open Collector Plus Alarm 1 5 Amp Form C Relay Output 1 Output 2 and Alarm 1 or Alarms 1 and 2 TABLE II Communications and Software Selections None Auxiliary Output Digital Inputs 1 Aux and 1 DI or 2 Dl RS 485 Modbus Plus Auxiliary Output Digital Inputs 10 Base T Ethernet Modbus RTU Plus Auxiliary Output Digital Inputs Standard Functions Single Display Dual Display with Auto Manual Set Point Programming 12 Segments Dual Display Auto Manual Limit Controller Includes Dual Display Option Reserved No Selection Infrared interface Nene Infrared Interface Included Can be used with a Pocket PC Communications Software Selections UDC2500 Universal Digital Controller Product Manual March 2012 Installation 51 51 16U 79 Issue 17 Page 2 of 3 Availability DC 2500 2501 TABLE Ill Input 1 can be changed in the field using external resistors TC RTD mV 0 5V 1 5V TC RTD mV 0 5V 1 5V 0 20mA 4 20mA
85. adiator Available only for Radiamatic inputs March 2012 UDC2500 Universal Digital Controller Product Manual 59 Configuration 3 10 Input 2 Set Up Group Introduction This data deals with various parameters required to configure Input 2 Function Prompts Table 3 10 INPUT2 Group Numeric Code 700 Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition eee pees Code INPUT 2 ACTUATION TYPE This selection determines what actuation you are going to use for Input 2 DIS Disable 0 20 0 to 20 mA internal dropping resistor 4 20 4 to 20 mA internal dropping resistor 0 5 0 to 5 Volts 1 5 1 to 5 Volts 0 2 0 to 2 Volts lisse XMITR2 TRANSMITTER CHARACTERIZATION Same as Input 1 Transmitter 60 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code ATTENTION The control setpoint will be 999 to 9999 floating in engineering units limited by the range of units selected here IN2 LO 999 to 9999 INPUT 2 LOW RANGE VALUE in floating in engineering units is displayed for all inputs engineering units but can only be configured for linear or RATIO2 m 20 0 to 20 0 1 INPUT 2 HIGH RANGE VALUE in engineering units is displayed for all inputs but can only be configured for linear or square root
86. ailable via the stocking program and must be ordered by model selection March 2012 UDC2500 Universal Digital Controller Product Manual 13 Installation 51 51 16U 79 Honeywell Issue 17 Page 3 of 3 UDC2500 Supplemental Universal Digital Controller Accessories amp Kits SPP includes Dual Display Auto Manual MCU Inputs PWA with 2nd Input and IR for Controllers 51452801 503 MCU Inputs PWA with IR for Limit Controllers 51452801 504 Electro Mechanical Relay 30755306 501 Varistor MOV 120 Vac Configuration Cable Kit used when IR is not specified Limit Controller Manual 14 UDC2500 Universal Digital Controller Product Manual March 2012 Installation 2 4 Control and Alarm Relay Contact Information Control Relays ATTENTION Control relays operate in the standard control mode that is energized when output state is on Table 2 2 Control Relay Contact Information Control Relay Control Relay Output 1 or 2 Wiring Contact Indicator Status N O Open N C Closed a Alarm Relays ATTENTION Alarm relays are designed to operate in a failsafe mode that is de energized during alarm sate This results in alarm actuation when power is OFF or when initially applied until the unit completes self diagnostics If power is lost to the unit the alarms will de energize and thus the alarm contacts will close Table 2 3 Alarm Relay Contact Information Alarm Relay Relay Contact March 2012 UDC2500 Universal
87. al Controller Product Manual 11 Installation 2 3 Model Number Interpretation Introduction Write your controller s model number in the spaces provided below and circle the corresponding items in each table This information will also be useful when you wire your controller 12 Figure 2 1 Model Number Interpretation 51 51 16U 79 Honeywell lesu 17 Page 1 of 3 UDC2500 Universal Digital Controller Model Selection Guide New Easy To Use UDC2500 1 4 DIN Single Loop Controller The UDC2500 Controller packs new powerful features while retaining all the simplicity flexibility and the industry standard HMI of the UDC2300 Controller that it replaces Many new optional features include NEMA 4X IP66 Front Face Built in infrared communications port for configuring with a Pocket PC or Laptop PC Based Configuration Tools Ethernet Communications Limit Model Available Thermocouple Health Monitoring Accutune III Fast Slow Heat Cool Instructions Select the desired key number The arrow to the right marks the selection available Make the desired selections from Tables through VI using the column below the proper arrow A dot denotes availability Key Number i ll i il i Iv Vv i KEY NUMBER UDC2500 Single Loop Controller Description Digital Controller for use with 90 to 250Vac Power Digital Controller for use with 24Vac dc Power Selection Avail
88. al Data Value The value referenced at the addressed device location is no within range Slave Device Failure The addressed device has not been able to process a valid message due to a bad device state Slave Device Busy The addressed device has ejected a message due to a busy state Retry later 07 NAK The addressed device cannot process the current Negative Acknowledge message Issue a PROGRAM POLL to obtain device dependent error data Buffer Overflow The data to be returned for the requested number of registers is greater than the available buffer space Function Code 20 only 222 UDC2500 Universal Digital Controller Product Manual March 2012 Ethernet TCP IP 11 Ethernet TCP IP 11 1 Overview Ethernet parameters can only be configured via the Process Instrument Explorer software Ethernet IP Address is 10 0 0 2 as shipped from the Factory The MAC address is printed on the case label of each instrument When constructing a network 1t is recommended that a Switch be used to connect UDCs to a LAN rather than using a Hub This is because a Switch passes only those messages for IP addresses that are connected to the Switch while a Hub passes all message traffic Using a Switch thus improves the overall throughput of the traffic to and from the UDCs March 2012 UDC2500 Universal Digital Controller Product Manual 223 Further information 12 Further information 12 1Modbus RTU Serial Communications Refer to Honeywell
89. ally be found by opening a DOS shell and typing ping smtp your domain name and extension i e ping smtp your_isp com UDC2500 Universal Digital Controller Product Manual March 2012 Configuration The content of the Emails sent by this controller contains the Alarm that triggered the Email its settings and the current value if applicable of the monitored variable For example the content of an Email triggered by Alarm 1 Setpoint 1 that is configured to monitor Input 1 would look something like this Name Alarm 1 SP1 Type INPUT1 Event HIGH END Value 500 00 Actual 712 69 The content of an Email triggered by Alarm 2 Setpoint 1 that is configured to monitor Digital Input 1 would look something like this Name Alarm 2 SP1 Type DIG IN1 Event HIGH END Value 0 00 Actual 0 00 ATTENTION Email will always be time stamped with the date that the Ethernet Software in the instrument was last modified If the SMTP address on your network is changed such as can happen when a server is replaced then you must reconfigure the Email SMTP IP address in this instrument to match the new IP address March 2012 UDC2500 Universal Digital Controller Product Manual 87 Configuration 3 17 Configuration Record Sheet Enter the value or selection for each prompt on this sheet so you will have a record of how your controller was configured TUNING PB or GAIN 1 0 ALGOR CTRALG PIDA RATE T 0
90. alue When making a setpoint change this is the rate at which the controller will change from the original setpoint up to the new one The ramping current setpoint can be viewed as SPn in the lower display Entering a 0 will imply an immediate change in Setpoint i e no rate applies 41 Configuration Function Prompt Lower Display Selection or Range of Setting Upper Display Numeri c Code EUHRDN 206 0 to 9999 in Engineering units per hour Parameter Definition RATE DOWN Rate down value When making a setpoint change this is the rate at which the controller will change from the original setpoint down to the new one The ramping current setpoint can be viewed as SPn in the lower display Entering a O will imply an immediate change in Setpoint i e no rate applies SPPROG optional feature SP Ramp must be disabled for SP Program prompts to appear If SP Rate is enabled it does not operate while an SP Program is running STRSEG E ul m uk 207 RECYCL SOKDEV 42 1to11 2 to 12 always end in a soak segment SOK 2 SOK 4 SOK 6 SOK 8 SOK 10 0 to 100 recycles 0 to 100 LAST Hold at last SP FSAF Manual mode failsafe SETPOINT RAMP SOAK PROGRAM Available only with controllers that contain this option SP RAMP must be disabled DISABLE Disables setpoint programming ENABLE Enables setpoint programming ATTENTION Detailed information fo
91. and a Remote Setpoint Refer to Subsection 3 11 Control Set Up Group for configuration details Changing the Setpoints Table 4 9 Procedure for Changing the Local Setpoints step operon press mean 1 Select the Until you see Setpoint Upper Display PV Lower Display SP or 2L Value 2 Change the To change the Local Setpoint to the value at which you want Value the process maintained The display blinks if you attempt to enter setpoint values beyond the high and low limits 3 Return to PV To store immediately or will store after 30 seconds Display 102 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Switching between setpoints You can switch Local and Remote setpoints or between two Local setpoints when configured ATTENTION The REMOTE SETPOINT value cannot be changed at the keyboard Table 4 10 Procedure for Switching Between Setpoints se Operation Pros Rem 1 Select the PTA Toalternately select Local Setpoint 1 LSP and the Remote Setpoint Function Setpoint RSP or switch between the 2 Local Setpoints LSP and 2L ATTENTION KEY ERROR will appear in the lower display if e the remote setpoint or 2 local setpoint is not configured as a setpoint source e you attempt to change the setpoint while a setpoint ramp is enabled or e if you attempt to change the setpoint with the setpoint select fun
92. arch 2012 UDC2500 Universal Digital Controller Product Manual 9 Installation Specifications RS422 485 Modbus RTU Communications Interface Optional Baud Rate 4800 9600 19 200 or 38 400 baud selectable Data Format Floating point or integer Length of Link 2000 ft 600 m max with Belden 9271 Twinax Cable and 120 ohm termination resistors 4000 ft 1200 m max with Belden 8227 Twinax Cable and 100 ohm termination resistors Link Characteristics Two wire multi drop Modbus RTU protocol 15 drops maximum or up to 31 drops for shorter link length Ethernet TCP IP Communications Interface Optional Type 10Base T Length of Link 330 ft 100 m maximum Use Shielded twisted pair Category 5 STP CATS Ethernet cable Link Characteristics Four wire plus shield single drop five hops maximum IP Address IP Address is 10 0 0 2 as shipped from the Factory Recommended network configuration Use Switch rather than Hub in order to maximize UDC Ethernet performance Configuration Ethernet parameters are configured via the Process Instrument Explorer Email The capability to send an Email is provided This must be configured via the Process Instrument Explorer Infrared Communications Optional Type Serial Infrared SIR Length of Link 3 ft 1 m maximum for IrDA 1 0 compliant devices Baud Rate 19 200 or 38 400 baud selectable Power Consumption 18 VA maximum 90 to 250 Vac 12 VA maximum 24
93. as A1S1 VAL UDC2500 Universal Digital Controller Product Manual March 2012 Function Prompt Lower Display A2S1HL A2S1EV A2S2TY A2S2VA A2S1HL A2S1EV ALHYST March 2012 Numeric Code 1109 1109 Selection or Range of Setting Upper Display Value in engineering units 0 0 to 100 0 of span or full output as appropriate Numeric Code 0 1 0 1 0 1 0 1 Configuration Parameter Definition ALARM 2 SETPOINT 1 STATE Same as A1S1HL ALARM 2 SEGMENT EVENT 1 Same as A1S1EV ALARM 2 SETPOINT 2 TYPE Select what you want Setpoint 2 of Alarm 2 to represent The selections are the same as A1S1TYPE ATTENTION Not applicable with Relay Duplex unless using Dual Relay PWA ALARM 2 SETPOINT 2 VALUE T his is the value at which you want the alarm type chosen in prompt A2S2TYPE to actuate The details are the same as A1S1 VAL ALARM 2 SETPOINT 1 STATE Same as A1S1HL ALARM 2 SEGMENT EVENT 2 Same as A1S1EV ALARM HYSTERESIS A single adjustable hysteresis is provided on alarms such that when the alarm is OFF it activates at exactly the alarm setpoint when the alarm is ON it will not deactivate until the variable is 0 0 to 100 away from the alarm setpoint Configure the hysteresis of the alarms based on INPUT signals as a of input range span Configure the hysteresis of the alarm based on OUTPUT signals as a of the full scale output range UDC2500
94. ash TUNE as long as ACCUTUNE process is operating When process completes tuning parameters are calculated and lower display will show NoTune prompt Table 4 15 Procedure for Using MANUAL TUNE for Cool side of Duplex Control sep Operation Press res Pious Configure LSP2 Switch to Automatic Mode Show Tuning Prompt Initiate Tuning Tuning in operation Until 2SP Local Setpoint 2 shows in the lower display Until LSP2 is a value within the Cool Zone output below 50 Until the A indicator is lighted on controllers with Manual option Until NoTUNE is shown on lower display Select DoSLOW or DoF AST in lower display Upper display will flash TUNE as long as ACCUTUNE process is operating When process completes tuning parameters are calculated and lower display will show NoTune prompt March 2012 UDC2500 Universal Digital Controller Product Manual 109 Monitoring and Operating the Controller 4 11 6 Error Codes Table 4 16 Procedure for Accessing Accutune Error Codes sep Operaion press mea 1 Select Accutune C setup Upper Display SET Set up Group Na Lower Display ATUNE 2 Go to Error Code Function Upper Display an error code Prompt NUA Lower Display ATERR Table 4 17 lists all the error codes definitions and fixes Table 4 17 Accutune Error Codes Error Code Upper Display Definition RUN ACCUTUNE
95. ated copper leads of equal length for connecting the decade box to the controller Milliampere e A calibrating device with at least 0 02 accuracy for use as a Millivolt Volts and signal source Radiamatic e Two insulated copper leads for connecting the calibrator to the controller e Place current source at zero before switching ON e Do not switch current sources OFF ON while connected to the UDC2500 input 5 4 Input 1 Set Up Wiring Thermocouple Inputs Using an Ice Bath Refer to Figure 5 2 and wire the controller according to the procedure given in Table 5 4 Table 5 4 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath 1 Connect the copper leads to the calibrator 2 Connect a length of thermocouple extension wire to the end of each copper lead and insert the junction points into the ice bath 3 Connect the thermocouple extension wires to the terminals for Input 1 See Figure 5 2 Millivolt Source Ice Bath Copper Leads Thermocouple Extension Wire Figure 5 2 Wiring Connections for Thermocouple Inputs Using an Ice Bath March 2012 UDC2500 Universal Digital Controller Product Manual 141 Input Calibration Thermocouple Inputs Using a Thermocouple Source Refer to Figure 5 3 and wire the controller according to the procedure given in Table 5 5 Table 5 5 Set Up Wiring Procedure for Thermocouple Inputs using Thermocouple Source 1 Connect the thermocouple extension wires to the t
96. aw the chassis and visually inspect the controller board and the inside of the case Refer to Section 2 Installation Installation instructions supplied with new board Table 7 6 explains how to troubleshoot Current Output failure symptoms 1 Table 7 6 Troubleshooting Current Output Failure Step What to do How to do it Make sure the controller is configured for Current output and the proper range 4 to 20 or 0 to 20 is configured Check the field wiring Check the output Recalibrate the Current Proportional output Change Current Output board Change Controller Make Output Set Up group function prompt OUT ALG CUR Make the Output Set UP group function prompt CRANGE 4 20 or 0 20 per your application Refer to Section 3 Configuration Output impedance must be less than or equal to 1000 ohms 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 Refer to Section 6 Output Calibration for details Installation instructions provided with new board March 2012 UDC2500 Universal Digital Controller Product Manual 169 Troubleshooting Service Procedure 3 Table 7 7 explains how to troubleshoot Position Proportional Output failure symptoms Table 7 7 Troubleshooting Three Position Step Control Output Failure Step What to do How to do it 1 Make certain that the controller
97. back slidewire wear dirt and noise e When operating in this algorithm the estimated OT display is shown to the nearest percent that is no decimal See Motor Travel Time the time it takes the motor to travel from 0 to 100 in section 3 8 Motor Position Display Table 4 21 Procedure for Displaying 3Pstep Motor Position sien operation press mee UUU E 1 Access the Y Lower Y Until you see Displays 3 Upper Display PV Lower Display OT The estimated motor position in 114 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller 4 16 Setting a Failsafe Output Value for Restart After a Power Loss Introduction If the power to the controller fails and power is reapplied the controller goes through the power up tests then goes to a user configured FAILSAFE OUTPUT VALUE Set a Failsafe Value Table 4 22 Procedure for Setting a Failsafe Value A Select Control setup Until you see Set up Group NA Upper Display SET Lower Display CONTRL 2 Select Failsafe Function You will see Function Prompt Naa Upper Display range within the range of the Output 0 to 100 for all output types except 3 Position Step 3 Position Step 0 motor goes to closed position 100 motor goes to open position Lower Display FAILSF 3 Select a value To select a failsafe output value in the upper display 4 Return to Normal At power up the output will go to
98. ber in engineering units above or below the setpoint outside of which the timer halts The range is 0 to 99 The decimal location corresponds to input 1 decimal selection This function determines whether LSP1 or PV is used as the setpoint when the program is initially changed from HOLD to RUN The selections are DISABL When the program is initially changed from HOLD to RUN the present LSP1 value is captured as the default setpoint If the program is terminated or the power cycled before the program has completed the LSP1 is used as the control setpoint The beginning segment uses this value as the initial ramp setpoint UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Program state Program termination state Reset Program to Beginning ENABL When the program is initially changed from HOLD to RUN the present PV value is captured and used as the beginning setpoint value for the ramp segment If the program is terminated before completion the setpoint value will revert back to the PV value captured at the initial HOLD to RUN transition If the power is cycled before program completion upon power up the setpoint is set to the PV value at power up and when the program is restarted that setpoint value is used initially The program state selection determines the program state after completion The selections are e DIS program is disabled so program value changed
99. bsection 3 4 Tuning Set Up Group e See Table 5 1 for Voltage vs Resistance equivalents or 0 and 100 range values CAUTION For linear inputs avoid step changes in inputs Vary smoothly from initial value to final 100 value Procedure The calibration procedure for Input 1 is listed in Table 5 10 The numeric codes are also listed Table 5 10 Input 1 Calibration Procedure Numeric Code 10000 sep operon press Rew 1 Enter Calibration Y Upper Display CAL Mode Y Lower Display INPUT1 10000 5 until you see p7 N You will see Upper Display DIS 0 Lower Display CALIN1 10001 N The calibration sequence is enabled and you will see Upper Display BEGN 1 Lower Display CALIN1 10001 At the completion of the sequence the selection automatically reverts to disable 2 Calibrate 0 You will see Upper Display APLY 2 Lower Display IN1ZRO 10002 7 NS e Adjust your calibration device to an output signal equal to the 0 range value for your particular input sensor See Table 5 1 for Voltage Degrees or Resistance equivalents for 0 range values e Wait 15 seconds then go to the next step March 2012 UDC2500 Universal Digital Controller Product Manual 145 Input Calibration ECU ress Pee 3 Calibrate 100 Function You will see EA Upper Display APLY 2 Lower Display IN1SPN 10003 e Adjust your calibration device to an output signal equal to
100. cations For this configuration the PV value is percent of range becomes the control output value which is used by any configured control output type When configured the upper display shows the PV while the lower display is blank unless more than one analog input is configured in which case the lower display shows the other analog inputs TIMER allows you to enable or disable the timer option The timer option allows you to configure a timeout period and to select timer start by either the keyboard RUN HOLD key or Alarm 2 A digital input can also be configured to start the timer When the timer is enabled it has exclusive control of the alarm 1 relay any previous alarm configuration is ignored At timeout the timer is ready to be re activated by whatever action has been configured Alarm 1 is activated at the end of the timeout period PERIOD allows you to configure the length of timeout period from 0 to 99 hours 59 minutes START allows you to select whether the timer starts with the keyboard Run Hold key or Alarm 2 50 UDC2500 Universal Digital Controller Product Manual March 2012 Function Prompt Selection or Range of Setting Lower Display Upper Display Numeric Numeric Code Code L DISP TREM 0 ET 1 INCRMT 407 Configuration Parameter Definition L DISP allows you to select whether time remaining TI REM or elapsed time E TIME is displayed for the timer option The time is shown on the lower
101. cket PC Figure 1 3 Depiction of infrared communications Figure 2 1 Model Number Interpretation Figure 2 2 Mounting Dimensions not to scale Figure 2 3 Mounting Methods Figure 2 4 Composite Wiring Diagram Figure 2 5 Mains Power Supply Figure 2 6 Input 1 Connections Figure 2 7 Input 2 Connections Figure 2 8 Electromechanical Relay Output Figure 2 9 Solid State Relay Output Figure 2 10 Figure 2 11 Figure 2 12 Figure 2 13 Figure 2 14 Figure 2 15 Figure 2 16 Figure 2 17 Figure 2 18 Figure 2 19 Open Collector Output Dual Electromechanical Relay Option Output Current Output Three Position Step Control Connections w o Dual Relay Option Three Position Step Control Connections with Dual Relay Option RS 422 485 Communications Option Connections Ethernet Communications Option Connections Auxiliary Output and Digital Inputs Option Connections Transmitter Power for 4 20 mA 2 wire Transmitter Using Open Collector Transmitter Power for 4 20 mA 2 Wire Transmitter Using Auxiliary Output Figure 3 1 Ethernet Configuration Screen Figure 3 2 Email Configuration Screen Figure 4 1 Operator Interface Figure 4 2 Functional Overview Block Diagram of the UDC2500 Controller Figure 4 3 Ramp Soak Profile Example Figure 4 4 Program Record Sheet March 2012 UDC2500 Universal Digital Controller Product Manual Introduction 198 199 201 204 205 206 207 210 212 214 216 217 220 222 xiii Introduction Figure 4 5
102. ction Contents Support and Contact NiO ni A da iv 1 INTRODUCTION cion ccwisdsdceuandasewesdvdacveadvanaweudwocts 1 LL OVERVIEW noet eerten a EEK Meacebssedacte iia 1 1 2 Function of Displays and Key comite 3 1 3 Process Instrument Explorer Software o oo eceeseesecsseceseceseceseeeseeeseeeeseeeaeesaaecsaecsaecsaecnseenseesseeeaes 4 1 4 CE Contormity Europe c0 aint ia ea ie iets 3 2 INSTALLATION oscars 7 Ds SONELVICW A A O O 7 212 Condensed Specilicat Om Seis ac 8 2 3 Model Number Interpretation 0 00 0 eee ceecesceeecencecesecssecesecsseesseesseesseeseaeeeaeeeseeeaaecaaecaeeaeeeaeens 12 2 4 Control and Alarm Relay Contact Information eee esseceseceseceneeseeeeeeeeaeeeaeeeaaecsaecaecnaeenaeens 15 2 5 Mounting neetan dbase IO 16 VO WAT a enron iE AEE E E AETR OA E E ROE EEEE E i ATE ei 18 2 641 Electrical Considerations tania 18 AR W mno Dragtassen A dida 20 3 GONFIGURA TION wisi civentrincvencusccdesccenavenducacusadnecedencuaecdescudssveaduancwencwacddecceanatauduas 33 Deli SOV OL VIC Wie sivas sods SewsiecescesnsdetiestS ave eadeve aa e IA 33 3 2 Configuration Prompt Hierarchy 000 cee ceeeecceeceeeseeeseeescecacecesecaecesecsseeeeceseeseneseaeeeaeeeaaecaaeesaeens 34 3 3 Contisuration Procedure ici A Meditate dni tee pen AAA det 35 34 Tuning Set Up Ordinaria tai till 36 33 SP Ramp Set Up Groupe aiii leia 40 3 0 Accutune Set Up GTO tra A di 44 3 37 Algorithm Set UP Group ii ri idas 47 3 8 Output S
103. ction Time Proportional Output has a resolution of 4 44 msec Cycle Time is adjustable from 1 second to 120 seconds CURRENT DUPLEX is similar to current simplex but uses a second current output The second output is usually scaled so that zero and span correspond with 0 and 50 output cool zone When the output is 0 to 50 the controller uses tuning parameter set 2 when the output is 50 to 100 it uses set 1 ATTENTION Other prompts affected 4 20 RNG CURRENT TIME DUPLEX is a variation of duplex with current active for 0 to 50 output tuning set 2 and time is active 50 to 100 output tuning set 1 Relay controls heat current controls cool ATTENTION Other prompts affected 4 20 RNG TIME CURRENT DUPLEX is similar to CUR TI except that current is active for 50 to 100 and time is active for 0 to 50 Relay controls cool current controls heat ATTENTION Other prompts affected 4 20 RNG CURRENT OUTPUT RANGE allows the RANGE f A user to easily select 4 20 mA output or 0 20 mA output operation without the need for recalibration of the instrument CURRENT DUPLEX RANGE ALGORITHM TRN 4 Oe S 29 Used with Output Algorithm selections CURD CURT or TCUR March 2012 UDC2500 Universal Digital Controller Product Manual 53 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code C
104. ction key disabled 4 10 Timer Introduction The Timer provides a configurable Time out period of from 0 to 99 hours 59 minutes or 0 to 99 minutes 99 seconds Timer Start is selectable as either the RUN HOLD key or Alarm 2 The Timer display can be either Time Remaining or Elapsed Time Configuration check Make sure e TIMER is enabled e A TIMEOUT period has been selected in hours and minutes or minutes and seconds e A TIMER FUNCTION START has been selected KEY or AL2 e A TIMER display has been selected Time remaining or Elapsed time e A timer increment selected e Timer reset selected Refer to Subsection 3 7 Algorithm Set Up Group for details March 2012 UDC2500 Universal Digital Controller Product Manual 103 Monitoring and Operating the Controller Viewing Times The times are viewed on the lower display as follows TIME REMAINING will show as a decreasing Hrs Min value HH MM or Min Sec value MM SS plus a counterclockwise rotating clock face ELAPSED TIME will show as an increasing Hrs Min value HH MM or Min Sec value MM SS plus a clockwise rotating clock face Operation When the Timer is enabled RUN HOLD key or ALARM 2 it has exclusive control of Alarm 1 relay At TIME OUT e Alarm l is active e The clock character has stopped moving e The Time display shows either 00 00 or the time out period depending on the configuration selection e The Timer is ready to be reset At
105. cutune III process assumes that Local Setpoint 1 will cause a Heating demand output above 50 and the tuning parameters calculated for that setpoint are automatically entered as PID SET 1 Likewise Accutune III assumes that Local Setpoint 2 will cause a Cooling demand output less than 50 and the tuning parameters calculated for that setpoint are automatically entered as PID SET 2 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Check for Duplex Monitoring and Operating the Controller See Subsection 3 6 Accutune Set Up Group for details Make sure e TUNE has been enabled e DUPLEX has been configured to Manual Automatic or Disabled 4 11 3 Using AUTOMATIC TUNE at start up for Duplex Heat Cool Used when DUPLEX has been configured for AUTOMATIC This is the preferred selection for most Heat Cool applications when tuning a new chamber This selection will sequentially perform both Heat and Cool tuning without further operator intervention Table 4 12 Procedure for Using AUTOMATIC TUNE at Start up for Duplex Control sep Operation press mesa 1 Configure LSP1 2 3 Configure LSP2 4 5 Switch to Automatic Mode 6 Show Tuning Prompt 7 Initiate Tuning Tuning in operation Until SP Local Setpoint 1 shows in the lower display Until LSP1 is a value within the Heat Zone output above 50 Until 2SP Local Setpoint 2 shows in the lower display Until LSP2 is
106. d lockout may be changed in the Set Up mode However knowledge of a security code number 0 to 9999 may be required to change from one level of lockout to another When a controller leaves the factory it has a security code of 0 which permits changing from one lockout level to another without entering any other code number Procedure If you require the use of a security code select a number from 0001 to 9999 and enter it when the lockout level is configured as NONE Thereafter that selected number must be used to change the lockout level from something other than NONE ATTENTION Write the number on the Configuration Record Sheet in the configuration section so you will have a permanent record March 2012 UDC2500 Universal Digital Controller Product Manual 91 Monitoring and Operating the Controller Table 4 1 Procedure to Enter a Security Code AAA o A 1 Enter Set Up Upper Display SET UP Mode Lower Display TUNING or 2 Select any Set Up Group Upper Display 0 Lower Display SECUR 5 NS 3 Security Code Entry To enter a four digit number in the upper display 0001 to 9999 b oI This will be your security code kK 4 4 Lockout Feature Introduction The lockout feature in the UDC2500 is used to inhibit changes via keyboard of certain functions or parameters by unauthorized personnel Lockout levels There are different levels of Lockout depending on the level of security
107. display in HH MM format along with a rotating clock character e If the clock rotation is clockwise elapsed time is indicated e If the clock rotation is counterclockwise time remaining is indicated RESET TIMER determines how the Timer will be set back to zero KEY Reset Timer via Run Hold Key ALARM 1 Reset the Timer via either Alarm 1 or Run Hold Key INCREMENT This selection determines how the timer s count will increment MINUTES Counts are in Hours Minutes SEC Counts are in Minutes Seconds March 2012 UDC2500 Universal Digital Controller Product Manual 51 Configuration 3 8 Output Set Up Group Introduction This group deals with various output types in the controller the Digital Output Status and the Current Output operation ATTENTION The Tuning Group is automatically configured to have two PID sets when a Duplex Control Algorithm is selected Function Prompts Table 3 8 OUTPUT Group Numeric Code 500 Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code OUTALG 501 The OUTPUT ALGORITHM lets you select the type of output you want Not applicable with Control algorithm prompt TPSC Three Position Step Control Selections are hardware dependent For example if the controller does not have a current output then none of the prompts for Output Algorithms that need a current out
108. document 51 52 25 66 Modbus RTU Serial Communications User Manual 12 2Modbus Messaging on TCP IP Refer to Honeywell document 51 52 25 121 MODBUS Messaging on TCP IP Implementation Guide 12 3How to Apply Digital Instrumentation in Severe Electrical Noise Environments Refer to Honeywell document 51 52 05 01 How to Apply Digital Instrumentation in Severe Electrical Noise Environments 224 UDC2500 Universal Digital Controller Product Manual March 2012 13 Index A Aborting Accutune 109 Accutune Error Codes 109 Accutune Error Status 45 Accutune lii 104 Accutune Set Up Group 43 82 Adaptive Tune 44 Alarm Blocking 81 Alarm Hysteresis 80 Alarm Outputs 9 Alarm Relay Output Failure 170 Alarm Relays 14 Alarm Setpoints 112 Alarm Setpoints Display 112 Alarms Set Up Group 76 Algorithm Set Up Group 46 Analog Inputs 8 Annunciators 93 Application Related Problems 159 Atune Group 44 82 Auto Manual Key 92 Automatic With Local Setpoint 100 Automatic With Remote Setpoint 100 Auto Only Mode 97 Autotune ls Complete 110 Auxiliary Output Calibration 154 Auxiliary Output Calibration Procedure 155 Auxiliary Output Connections 30 Auxiliary Output Failure 173 B Background Tests 162 Baud Rate 73 Bias 57 60 Blended Tune 107 Burnout Protection 57 C Calibration Mode 149 156 Calibration Steps 137 CE Conformity Europe 5 Changing Control Modes 101 Changing The Local Setpoints 101
109. e Supply O The dropping resistor for milliamp inputs is internal to the controller Figure 2 7 Input 2 Connections Time Simplex i Output ENC o TT ERA Load ZO LA Relay t Ey oy ASLE Relay Loadj o O Supply Ta IR To terminalon o o o Power Q 6 19 or 21 7 Alarm n o Relay 2 23 LI Load _0 Relay Load yer Power o To terminal 4or6 Load _ Relay Load Q Supply Power on To terminal 7org Load Relay Load O Supply To terminal Power rs esf e L1 Relay 1 L N O O 19 or 21 Q Load _2 Relay Load Supply Power o To terminal es 4or6 Load _ Relay Load Supply Power EE Tosen O Alarm 2 is not available with Time Proportional Duplex or Three Position Step Control unless the Dual Relay Option is used O Electromechanical relays are rated at 5 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Figure 2 8 Electromechanical Relay Output See Table 2 6 for relay terminal connections for other Output Algorithm Types March 2012 UDC2500 Universal Digital Controller Product Manual 25 Installation Time Simplex Output Relay 1 Load 24 Relay Load Supply Power Ja ES To terminal 4or6 Load Relay Load Supply Power ad ES To terminal 70r9 O Dummy Resistor Load Supply Power _2 e Load o o Relay Load Supply To terminal Power ee 7
110. e Source 141 Thermocouple Inputs Using An Ice Bath 140 Three Position Step 48 Three Position Step Control Algorithm 113 Three Position Step Control Connections 28 Three Position Step Control Output Failure 167 Time Current Duplex 52 Time Duplex 52 Time Proportional Output 51 Time Proportional Output Failure 168 Time Remaining 103 Time Simplex 51 Time Out 103 Timer 102 Timer 49 Transmitter Characterization 56 Transmitter Power For 4 20 Ma 31 228 UDC2500 Universal Digital Controller Product Manual Troubleshooting Aids 159 Troubleshooting Procedures 165 Troubleshooting Service 158 Tune 44 104 Tune For Duplex Heat Cool 105 Tuning 35 Tuning Indicators 104 Tuning Parameter Sets 61 Tuning Set Up Group 35 Two Sets Of Tuning Constants 110 TX Delay 74 U Universal Output Functionality And Restrictions 20 V Voltage And Resistance Equivalents For 0 And 100 Range Values 137 139 W X Y Z Weigh 10 Wiring 17 Wiring Bundling 18 Wiring Connections For 1 To 5 Volt Input Input 2 147 Wiring Connections For 4 To 20 Ma Input Input 2 146 Wiring Connections For Calibrating Auxiliary Output 154 Wiring Connections For Calibrating Current Output 152 Wiring Connections For Radiamatic Milliampere Millivolts Or Volts Except 0 To 10 Volts 142 143 Wiring Connections For Rtd Resistance Thermometer Device 141 Wiring Diagrams 19 Wiring The Controller
111. e contact is closed at power up the unit will automatically restart the SP Ramp or Program at the captured Setpoint value DI1COM DIGITAL INPUT 1 COMBINATION SELECTIONS This selection allows the specified function to occur in addition to the one chosen for DIG IN 1 DISABLE Disables combination function PLUS PID2 Contact closure selects PID Set 2 PLUS DIRECT ACTION Contact closure selects direct controller action PLUS SETPOINT 2 Contact closure puts the controller into setpoint 2 PLUS SETPOINT 1 Contact closure puts the controller into setpoint 1 PLUS RUN SETPOINT PROGRAM RAMP Contact closure starts SP Program Ramp if enabled 907 Same selections as DIGITAL INPUT 2 SELECTIONS for Digital Input 1 DI2COM 908 Same selections as DIGITAL INPUT 2 COMBINATIONS Digital Input 1 Combinations March 2012 UDC2500 Universal Digital Controller Product Manual 73 Configuration 3 13 Communications Group Introduction The Communications group lets you configure the controller to be connected to a host computer via Modbus or Ethernet TCP IP protocol Two parameters in this Group Communications Station Address and TX Delay are also used for IR communications No other parameters affect IR communications Introduction A controller with a communications option looks for messages from the host computer If these messages are not received within the configured shed time the controller will SHED from the communicatio
112. e Proportional P term of the PID algorithm GAIN selects the unitless term of gain for the P term of the PID algorithm Where GAIN 100 FS PB PROPORTIONAL BAND selects units of percent proportional band for the P term of the PID algorithm Where PB 100 FS GAIN RESET UNITS Selects units of minutes per repeat or repeats per minute for the I term of the PID algorithm 20 Repeats per Minute 0 05 Minutes per Repeat MINUTES PER REPEAT The time between each repeat of the proportional action by reset REPEATS PER MINUTE The number of times per minute that the proportional action is repeated by reset NOTE 2 If controller is in Manual upon failure output will maintain its value at time of failure NOTE 3 These selections appear when the Control Algorithm is selected for 3PSTEP NOTE 4 The local setpoint will automatically adjust itself to be within the setpoint limit range For example if SP 1500 and the SP HILIM is changed to 1200 the new local setpoint will be 1200 NOTE 5 Reset limits and Dropoff are not displayed when Three Position Step Control is configured March 2012 UDC2500 Universal Digital Controller Product Manual 67 Configuration 3 12 Options Group Introduction The Options group lets you configure the remote mode switch Digital Inputs to a specific contact closure response or configure the Auxiliary Output to be a specific selection with desired scaling Function Prompt
113. e blinking by pressing the RUN HOLD key The messages will still be available for viewing by pressing the LOWER DISPLAY key Table 7 3 Background Tests Lower Reason for Failure How to Correct the Problem Display E FAIL Unable to write to non volatile 1 Check the accuracy of the parameter and re memory Anytime you change a parameter and it is not accepted you will see E FAIL enter Try to change something in configuration Run through Read STATUS tests to re write to EEPROM FAILSF This error message shows whenever Run through STATUS check to determine the the controller goes into a failsafe reason for the failure mode of operation This will happen if 2 Press the SET UP key until STATUS appears Pa test qe oe in the lower display Oe eae _ Press the FUNCTION key to see whether the e Calibration test failed lost fail th th h th Burnout configured for none ss a alk nen da ae E th and the input failed codes a second time to see if the error cleared INIRNG Input 1 out of range The process Make sure the range and actuation are input is outside the range limits configured properly Check the input source Restore the factory calibration See Subsection 0 Field calibrate See Section 5 Input Calibration IN1_FL Two consecutive failures of input 1 Make sure the actuation is configured integration i e cannot make analog correctly See Section 3 Configuration to digital con
114. e current setpoint value Press Ramp N Hold J again to continue 5 View the Y Lower N Until you see remaining ramp Display J Upper Display RUN or HOLD and the PV value time Lower Display RP xx HH MM time remaining March 2012 UDC2500 Universal Digital Controller Product Manual 117 Monitoring and Operating the Controller ste operation Pes a 6 End the Ramp When the final setpoint is reached RUN changes to HOLP in the upper display and the controller operates at the new final setpoint 7 Disable SPRAMP See Section 3 Configuration group SPRAMP for details Power Outage If power is lost during a ramp upon power up the controller will be in HOLD and the setpoint value will be the setpoint value prior to the beginning of the setpoint ramp The ramp is placed in hold at the beginning Configure the mode at Set Up Group CONTROL function prompt PWRUP See Subsection 3 11 CONTRL GROUP FUNCTION Prompts 4 20Setpoint Rate Introduction When you have configured a SETPOINT RATE it will apply immediately to local setpoint change Configuration check Make sure e SPRATE is enabled e SP RATE and SPPROG are not running e A Rate Up EUHRUP or Rate Down EUHRDN value has been configured in Engineering units per hour ATTENTION A value of 0 will imply an immediate change in setpoint that is NO RATE applies See Subsection 3 5 Configuration group SPRAMP for details Op
115. e field of the response All function codes have a most significant bit MSB of 0 their values are below 80 hex In an exception response the slave sets the MSB of the function code to 1 This makes the function code value in an exception response exactly 80 hex higher than the value would be for a normal response With the function code s MSB set the master s application program can recognize the exception response and can examine the data field for the exception code Data Field In a normal response the slave may return data or statistics in the data field In an exception response the slave returns an exception code in the data field This defines the slave condition that caused the exception March 2012 UDC2500 Universal Digital Controller Product Manual 221 Modbus Read Write and Override Parameters plus Exception Codes Query Example Internal slave error reading 2 registers starting at address 1820h from slave at slave address 02 02 03 18 20 00 02 CRC CRC Response Example Return MSB in Function Code byte set with Slave Device Failure 04 in the data field 02 83 04 CRC CRC Table 10 21 Modbus RTU Data Layer Status Exception Codes Exception Definition Description Code Illegal Function The message received is not an allowable action for the addressed device Illegal Data Address The address referenced in the function dependent data section of the message is not valid in the addressed device Illeg
116. e following table lists those symbols used in this document to denote certain conditions Symbol Definition CAUTION Uy Ps gt o lt UE E continued ATTENTION Identifies information that requires special consideration TIP Identifies advice or hints for the user often in terms of performing a task Indicates a situation which if not avoided may result in equipment or work data on the system being damaged or lost or may result in the inability to properly operate the process CAUTION Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury It may also be used to alert against unsafe practices CAUTION symbol on the equipment refers the user to the product manual for additional information The symbol appears next to required information in the manual WARNING Indicates a potentially hazardous situation which if not avoided could result in serious injury or death WARNING symbol on the equipment refers the user to the product manual for additional information The symbol appears next to required information in the manual WARNING Risk of electrical shock Potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms 42 4 Vpeak or 60 VDC may be accessible ESD HAZARD Danger of an electro static discharge to which equipment may be sensitive Observe precautions for handling electrostatic sensitive devices Protective Earth PE ter
117. e the current selection to another selection 3 Scroll through Function until the lower display rolls through the rest of the functions and Functions pcia returns to Upper Display the new selection Lower Display INxTYP 150 UDC2500 Universal Digital Controller Product Manual March 2012 Input Calibration ECU ress Ree A or until you change the input selection in the upper display back to the proper selection You will see Upper Display Original Input Selection that matches your type of sensor Lower Display INxTYP 4 Return to Normal Pana to return to Normal operating mode Operation QB The factory calibration will be restored If the problem is not corrected contact the Honeywell Technical Assistance Center at 1 800 423 9883 USA and Canada March 2012 UDC2500 Universal Digital Controller Product Manual 151 Output Calibration 6 Output Calibration 6 1 Overview Introduction This section describes the field calibration procedures for the following types of outputs e Current Output e Auxiliary Output What s in this section The following topics are covered in this section 6 3 Auxiliary Output Calibration 6 4 Restore Output Factory Calibration A WARNING SHOCK HAZARD OUTPUT CALIBRATION 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 CALIBRATION March 2012 UDC2500 Univer
118. ectrical Noise Environments Permissible Wiring Bundling Table 2 5 Permissible Wiring Bundling Bundle No Wire Functions OE 1 e Line power wiring e Earth ground wiring e Line voltage control relay output wiring e Line voltage alarm wiring 2 Analog signal wire such as e Input signal wire thermocouple 4 to 20 mA etc e 4 20 mA output signal wiring Digital input signals 3 e Low voltage alarm relay output wiring e Low voltage wiring to solid state type control circuits e Low voltage wiring to open collector type control circuits March 2012 UDC2500 Universal Digital Controller Product Manual 19 Installation 2 7 Wiring Diagrams Identify Your Wiring Requirements To determine the appropriate diagrams for wiring your controller refer to the model number interpretation in this section The model number of the controller is on the outside of the case Universal Output Functionality and Restrictions Instruments with multiple outputs can be configured to perform a variety of output types and alarms For example an instrument with one current output and two relays can be configured to provide any one of the following 1 Current Simplex with two alarm relays 2 Current Duplex 100 with two alarm relays 3 Time Simplex with one alarm relay 4 Time Duplex with no alarm relays 5 Three Position Step Control with no alarm relays These selections may all be made via the keyboard and by wiring to the appropriate output termina
119. er e Create edit configurations live just connect software to controller via comm port e Create edit configurations offline and download to controller later via comm port e Port types available on every UDC2500 o Infrared o RS 485 o Ethernet e Same port types on UDC3200 and UDC3500 allow interconnectivity e This software is available in English Italian German and French Communication Setup Upload 9 La Emo Offline Download Configuration ses BE es a Online Maintenance ee Data iiaea Mema Figure 1 2 Screen capture of Process Instrument Explorer running on a Pocket PC Infrared communications The infrared connection provides a non intrusive wireless connection with the instrument and maintains NEMA4X AND IP66 integrity 4 UDC2500 Universal Digital Controller Product Manual March 2012 Introduction No need to get access to the back of the controller to communicate with the instrument no need to take your screw driver to wire the communication cable no wiring mistake possible You can now duplicate an instrument s configuration upload or download a new configuration in a matter of seconds just by pointing your Pocket PC in the direction of the instrument It takes just a few seconds to upload a configuration from an instrument You can then save the configuration file onto your PC or pocket PC for review modification or archiving Furthermore this software also gives you important main
120. erating parameters that meet you process control needs now and change them later to meet new ones March 2012 UDC2500 Universal Digital Controller Product Manual 1 Introduction Mount Anywhere This instrument is intended for industrial control applications It must be panel mounted with the wiring terminals enclosed within the panel The instrument is environmentally hardened and when suitably enclosed can be mounted anywhere in plant or factory on the wall or even on the process machine itself The front face is NEMA3 and IP55 rated and can be easily changed to NEMA4X and IP66 for the most severe hose down applications It withstands ambient temperatures up to 55 C 133 F and resists the effects of vibration and shock Figure 1 1 UDC2500 Operator Interface all display items shown 2 UDC2500 Universal Digital Controller Product Manual March 2012 Introduction 1 2 Function of Displays and Keys Table 1 1 shows each key on the operator interface and defines its function Table 1 1Function of Displays and Keys 9 NS Function Places the controller in the Configuration Set Up group select mode Sequentially displays Set Up groups and allows the FUNCTION key to display individual functions in each Set Up group Used in conjunction with the SET UP key to select the individual functions of a selected Configuration Set Up group Used during field calibration procedure Selects an op
121. erating parameter to be shown in the lower display See Section 4 5 2 for a list of the operating parameters and Section 4 5 3 for a list of the diagnostic messages EY Alternately selects AUTO Lower display automatically displays setpoint value in engineering units MAN Lower display automatically indicates output in RESET Only used on Limit Controllers to reset the Limit Relay e Setpoint Select Hold key down to cycle through configured setpoints 9 E7 Alternate action switch initiates or holds the Setpoint Ramp or Setpoint Program Acknowledges a latched alarm 1 Acknowledges Diagnostic Messages Increases the selected parameter value J Decreases the selected parameter value Note 1 Value can be changed if in manual mode For Three Position Step Control when a slidewire is not used the output value is the estimated motor position Note 2 Value can be changed via increment decrement keys Note 3 The selected set can be changed via increment decrement keys March 2012 UDC2500 Universal Digital Controller Product Manual 3 Introduction 1 3 Process Instrument Explorer Software Overview Process Instrument Explorer lets you configure your instrument on a desktop laptop or Pocket PC For details see Process Instrument Explorer manual 51 52 25 131 Features e Create configurations with intuitive software program running on either a Pocket PC a Desktop or a laptop comput
122. eration When a change to local setpoint is made this controller will ramp from the original setpoint to the target setpoint at the rate specified The current setpoint value can be viewed at Sn on the lower display Power outages If power is lost before the target setpoint is reached upon power recovery the controller powers up with Sn Current PV value and it automatically Restarts from Sn current PV value up to the original target setpoint 118 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller 4 21 Setpoint Ramp Soak Programming Introduction The term programming is used here to identify the process for selecting and entering the individual ramp and soak segment data needed to generate the required setpoint versus time profile also called a program A segment is a ramp or soak function which together make up a setpoint program Setpoint Ramp Soak Programming lets you configure six ramp and six soak segments to be stored for use as one program or several small programs You designate the beginning and end segments to determine where the program is to start and stop Review program data and configuration While the procedure for programming is straightforward and aided by prompts we suggest you read Program Contents Table 4 25 lists the program contents and an explanation of each to aid you in configuration Then refer to Subsection 3
123. erminals for Input 1 as shown in Figure 5 3 Thermocouple Source Thermocouple Extension Wire Figure 5 3 Wiring Connections for Thermocouple Inputs Using Thermocouple Source RTD Inputs Refer to Figure 5 4 and wire the controller according to the procedure given in Table 5 6 Table 5 6 Set Up Wiring Procedure for RTD Inputs 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 4 Decade Resistance Box Copper Leads Equal Length Figure 5 4 Wiring Connections for RTD Resistance Thermometer Device 142 UDC2500 Universal Digital Controller Product Manual March 2012 Input Calibration Radiamatic Millivolts Volts or Thermocouple Differential Inputs Refer to Figure 5 5 and wire the controller according to the procedure given in Table 5 7 Table 5 7 Set Up Wiring Procedure for Radiamatic Millivolts Volts or T C Differential Inputs Except 0 10 Volts 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 5 2 Place current voltage source at zero before switching on 3 Do not switch current voltage source ON OFF while connected to the instrument ATTENTION For Radiamatic inputs only set Emissivity value to 1 0 See Subsection 3 9 Configuration Set Up prompt INPUT1 function prompt EMISS Millivolt or Volt Source Figure 5 5 Wiring Connections for Radiamatic T C Differential Millivolts or Volts Except 0 to
124. es Minute Segment 2 Soak 003A 058 FP R W Within Setpoint Limits Setpoint Value Segment 2 Soak 003B 059 FP R W 99 59 0 99 Hrs 0 59 Min Time Segment 3 Ramp 003C 060 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degrees Minute Segment 4 Soak 003D 061 FP R W Within Setpoint Limits Setpoint Value Segment 4 Soak 003E 062 FP R W 99 59 0 99 Hrs 0 59 Min Time Segment 5 Ramp 003F 063 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degrees Minute Segment 6 Soak 0040 064 FP R W Within Setpoint Limits Setpoint Value Segment 6 Soak 0041 065 FP R W 99 59 0 99 Hrs 0 59 Min Time Segment 7 Ramp 0042 066 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degrees Minute Segment 8 Soak 0043 067 FP R W Within Setpoint Limits Setpoint Value 202 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Segment 8 Soak 0044 Segment 9 Ramp 0045 Segment 10 0046 Soak Setpoint Value Segment 10 0047 Soak Time Segment 11 0048 Ramp Time Segment 12 0049 Soak Setpoint Value Segment 12 Soak Time 068 FP R W 99 59 0 99 Hrs 0 59 Min 069 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degrees Minute 070 FP R W Within Setpoint Limits
125. es after segment 12 34 ATUNE ALGOR OUTALG INPUT1 EMSs INPUT2 CONTRL orto ACTON LOUTH Corto BRAND rs Case Eon Ls Poran mnnm OPTIONS COM ALARMS asi Caisiva ATSTAL MS1Ev MSA ATS VA Corsa mS 7 serv asua a aesTEv aesa save Cars ser gt gt Carat ata BLOCK BIAGAL DISPLY STATUS UDC2500 Universal Digital Controller Product Manual March 2012 Configuration 3 3 Configuration Procedure Introduction Each of the Set Up groups and their functions are pre configured at the factory The factory settings are shown in Table 3 4 through Table 3 15 that follow this procedure If you want to change any of these selections or values follow the procedure in Table 3 3 This procedure tells you the keys to press to get to any Set Up group and any associated Function parameter prompt Procedure ATTENTION The prompting scrolls at a rate of 2 3 seconds when the SET UP or FUNCTION key is held in Also 4 or W keys will move group prompts forward or backward at a rate twice as fast Table 3 3 Configuration Procedure sep operon press ea 1 Enter Set Up setup Upper Display SET Mode SA Lower Display TUNING This is the first Set Up Group title 2 Select any Set _ Sequentially displays the other Set Up group titles shown in Up Group NA the prompt hierarchy in Table 3 2 Configuration Prompt Hierarchy You can also use the 4 or w keys to
126. et Up Group 55 Input 1 Set Up Wiring 140 Input 2 Calibration Procedure 147 Input 2 Connections 24 Input 2 Set Up Group 59 Input 2 Set Up Wiring 146 147 Input Calibration 136 Installation 7 Installation Related Problems 159 Integer Parameter Type 181 Isolation 9 K Key Error 92 Key Lockout 92 Keyboard Failure 171 Keys 3 L Latching 115 Local Area Network Lan Settings 133 Local Setpoint Source 62 Lockout 37 Lockout Feature 91 Lockout Levels 91 Loop Data Alarm Details 127 Loop Data Digital Input Details 128 Loop Data Screen 126 Loopback Test 75 Lower Display Key Parameter Prompts 94 M Mains Power Supply 17 22 Manual 100 Manual Reset 36 Manual Tune 107 Manual Auto Key Lockout 38 Minimum And Maximum Range Values 137 Modbus Read Write And Override Parameters 189 Modbus RTU Exception Codes 218 Modbus RTU Function Codes 180 Model Number Interpretation 12 Monitoring T 89 Motor Position Display 113 Motor Time 54 Mounting 15 Mounting Method 16 Mounting Procedure 16 N Non Latching 115 March 2012 O Open Collector Output 26 Operating Parameters 94 Operator Interface 90 Option Status 191 Output Algorithm 51 Output Calibration 151 Output Limit 65 Output Set Up Group 51 Overriding Controller Setpoint 194 P Q P I E Tool 131 P I E Tool Ethernet And Email Configuration Screens 84 P I E Tool Maintenance Screen
127. et Up troup cesses cevetes sadessedaddersis sande tasacesteyantees od cccevesnanebebsabacesectaaceasscsceevash NE Een 52 3 97 Input 1 Set Up Group mus da ae a 56 3 10 Inputi2 Set Up Group s tc reas 60 3 11 Control Set Up Group viii tenes biden ane caged 62 3 12 Options Group neiss orete eee tail 68 JI Communications OO UP isis sec cs escien n e iie eke eea e E E E dida 74 March 2012 UDC2500 Universal Digital Controller Product Manual vii Introduction 3 14 Alarms Set Up Group mc dde 77 315 Display Set Up GTOUP emula Rave eleva Sas ee elation aa 83 3 16 P LE Tool Ethernet and Email Configuration Screens ee eeceesesseeeneeeseeensecnseceaecnaeenseenes 85 3 17 Configuration Record Sheet lt i eee ieed dae ivi rc 88 4 MONITORING AND OPERATING THE CONTROLLER ecceeeeeeseeeeeeeeees 90 AE CONCISA EN Weebly dia dr 90 4 2 A RS AN 91 4 3 Enterinhg a Security COdS nilicdiisili sal ecede stadaced bane ceseueteaeeea secede Soctanataaaaceseleccesatinacdes 91 44 Lockout Features innean i heen AA MAM et a oan naa 92 4 5 Monitoring Your Controller cuina A aiii 94 AST E O ONO 94 4 5 2 Viewing the operating paraMetelS oooooccnocococononnnonncnnnnonononanonncno nono noco nec nn cnn ncnnn nana rra cra crias 95 4 5 3 Diagnostic Messages sidonia iii pa it 96 4 6 Single Display Functional lisina pipi 98 4 7 Start Up Procedure for Operation sc achtiedeiatcasseenttiee eee dl tease ieee ieee 100 4 3 Control M
128. etpoint Limits Output Direction and Limits Deadband and Hysteresis Function Prompts Table 3 11 Table 3 12 CONTRL Group Numeric Code 800 Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code PIDSET 801 NUMBER OF TUNING PARAMETER SETS This selection lets you choose one or two sets of tuning constants gain rate and reset NOTE The Tuning Group is automatically configured to have two PID sets when a Duplex Control Algorithm is configured ONE 0 ONE SET ONLY Only one set of tuning parameters is available Configure the values for Gain proportional band Rate Reset Time and Cycle Time if time proportional is used 2KBD 1 TWO SETS KEYBOARD SELECTABLE Two sets of tuning parameters can be configured and can be selected at the operator interface or by using the Digital Inputs Press LOWER DISPLAY key until you see PID SET1 or PID SET2 then press Amor Ww to switch between sets Configure the values for Gain Rate Reset Cycle Time Gain 2 Rate 2 Reset 2 Cycle 2 Time 62 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code 2 PR 2 SP AUTOMATIC SWITCHOVER VALUE This is the value of Process Variable or Setpoint at which the controller
129. etting Upper Display Numeric Numeric Code Code TX_DLY 1 to 500 TX DELAY Configurable response delay timer milliseconds allows you to force the UDC to delay its response for a time period of from 1 to 500 milliseconds compatible with the host system hardware software This parameter is also used for the IR communications link WS_FLT Defines word byte order of floating point data for communications Byte values 0 1 2 3 seeeecee emmmmmmm mmmmmmmm mmmmmmmm Where s sign e exponent m mantissa bit SDENAB 1007 DIS SHED ENABLE Disables enables shed ENAB functionaliy SHDTIM 1008 0 to 255 SHED TIME The number that represents how Sample many sample periods there will be before the Periods controller sheds from communications Each period equals 1 3 seconds 0 equals No shed Note If ComSTA is set to MODBUS and if SHEDENAB is set to DISABL Shed Time will not be configurable SDMODE 1009 SHED CONTROLLER MODE AND OUTPUT LEVEL Determines the mode of local control you want when the controller is shed from the communications link LAST 0 LAST SAME MODE AND OUTPUT The controller will return to the same mode manual or automatic at the same output level that it had before shed MAN 1 TO MAN MANUAL MODE SAME OUTPUT The controller will return to manual mode at the same output level that it had before shed FSAFE 2 FSAFE MANUAL MODE FAILSAFE OUTPUT The controller will return to manual mode at the output
130. g Point Parameter Type Table 9 3 Register Address Format for Function Code 20 Table 9 4 Register Address Format for Function Code 21 Table 10 1 Control Data Parameters Table 10 2 Option Status Table 10 3 Miscellaneous Read Onlys Table 10 4 SetPoint Program Read Only Information Table 10 5 Setpoint Code Selections Table 10 6 Setpoint Associated Parameters Table 10 7 Computer Setpoint Selection xii UDC2500 Universal Digital Controller Product Manual 124 138 140 140 141 142 142 143 144 144 145 147 148 149 150 154 155 156 158 159 163 164 165 167 169 169 170 171 172 173 174 175 176 176 177 178 181 181 181 184 184 186 190 194 194 195 195 196 196 197 March 2012 Table 10 8 Computer Setpoint Associated Parameters Table 10 9 Set up Group Tuning Table 10 10 Table 10 11 Table 10 12 Table 10 13 Table 10 14 Table 10 15 Table 10 16 Table 10 17 Table 10 18 Table 10 19 Table 10 20 Table 10 21 Set up Group Setpoint Ramp Rate Set up Group Accutune Set up Group Algorithm Set up Group Output Set up Group Input 1 Set up Group Input 2 Set up Group Control Set up Group Options Set up Group Communications Set up Group Alarms Set up Group Display Modbus RTU Data Layer Status Exception Codes Figures Figure 1 1 UDC2500 Operator Interface all display items shown Figure 1 2 Screen capture of Process Instrument Explorer running on a Po
131. ges of certain functions or parameters TCWARN Thermocouple sensor is starting to burnout TCFAIL Thermocouple sensor is in imminent danger of burning out OUT1 FL Current Output 1 is less than 3 5 mA OUT2 FL Current Output 2 is less than 3 5 mA The Thermocouple Error messages can be disabled via the TCDIAG configuration in the DISPLAY setup group The Current Output Error messages can be disabled via the DIAGAL configuration in the ALARM setup group 96 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller RSP Source PV Source Remote SP a CONTROL ALGORITHM Local SP To Final Control Element yyy e SP o CSP 2SP OUTPUT Figure 4 2 Functional Overview Block Diagram of the UDC2500 Controller March 2012 UDC2500 Universal Digital Controller Product Manual 97 Monitoring and Operating the Controller 4 6 Single Display Functionality Introduction This means that the displayed value of PV Setpoint Setpoint2 Remote Setpoint Input 2 Output Bias Aux Out and Deviation will appear on the top display and a prompt identifying the value will appear on the bottom display Access the Values Pressing the LOWER DISPLAY key will cycle through all applicable values configuration dependent One minute after the last press of the display key the display will revert back to a configured default display The default display is configured in the Input
132. he 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 Make sure the NO or NC contact wiring is correct Refer to Section 2 Installation for relay contact information Installation instructions supplied with the new relay or board Installation instructions supplied with the new board March 2012 UDC2500 Universal Digital Controller Product Manual 173 Troubleshooting Service Procedure 7 Table 7 11 explains how to troubleshoot a Keyboard failure Table 7 11 Troubleshooting a Keyboard Failure Step What to do How to do it 1 4 Make sure the keyboard is connected properly to the MCU output and power input boards Controller Keyboard or specific keys may be LOCKED OUT via the security code Run the keyboard test Replace the display keyboard if any keys do not function Withdraw the chassis from the case and visually inspect the connection Use your four digit security code number to change the lockout level Refer to Section 3 Configuration Press the SET UP key and hold in then press the FUNCTION key at the same time The controller will run a display test Then you will see Upper Display KEYS Lower Display TRY ALL Press each key If it works the
133. hm Set Up group Because a proportional controller will not necessarily line out at setpoint there will be a deviation offset from setpoint This eliminates the offset and lets the PV line out at setpoint ATTENTION Bias is shown on the lower display MANRST PB 2 or GAIN 2 RATE2T March 2012 UDC2500 Universal Digital Controller Product Manual 37 PROPORTIONAL BAND 2 or GAIN 2 RATE 2 and RESET 2 parameters are the same as previously described for Heat except that they refer to the cool zone tuning constants on duplex models or the second set of PID constants whichever is pertinent PB 0 1 to 1000 Gain 0 01 to 1000 This is the same as above except that it applies to Duplex models for the COOL zone of Heat Cool applications or for the second set of PID constants 0 00 to 10 00 minutes 0 08 or less OFF Configuration 0 02 to 50 00 Function Prompt Selection or Range of Setting Lower Display Upper Display Numeric Numeric Code Code i i CYC2T2 or 1 to 120 CT2 X3 111 0 02 to 50 00 0 to 9999 l NONE 0 LOCK Parameter Definition These are the same as above except that they apply to Duplex models for the COOL zone of Heat Cool applications or for the second set of PID constants CYCLE TIME HEAT determines the length of one time proportional output relay cycle Defined as HEAT cycle time for Heat Cool applications CYC T1 Electromechanical relays CT1 X3
134. hooting error message prompts and controller failure symptoms to identify typical failures which may occur in the controller Follow the troubleshooting procedures to correct them 7 2 Troubleshooting Aids Overall error messages An error message can occur e At power up See Subsection 7 3 e When the Status Tests are requested See Subsection 7 4 e During continuous background tests while in normal operation See Subsection 7 5 Controller failure symptoms Other failures may occur that deal with the Power Output or Alarms Refer to the controller failure symptom in Table 7 4 to determine what is wrong and the troubleshooting procedures to use to correct the problem Check installation If a set of symptoms still persists refer to Section 2 Installation and ensure proper installation and proper use of the controller in the system 162 UDC2500 Universal Digital Controller Product Manual March 2012 Troubleshooting Service Customer support If you cannot solve the problem using the troubleshooting procedures listed in this section you can get technical assistance by dialing 1 800 423 9883 USA and Canada An engineer will discuss your problem with you Please have your complete model number serial number and Software version available The model and serial numbers can be found on the chassis nameplate The software version can be viewed under Setup Group Status See Table 7 1 If it is determined that a hardware problem e
135. igital configuration register addresses 0080 through OOFA are updated via communications the non volatile memory is updated as soon as the message is received Communications Transfer Rates e Reads minimum 20mS and writes minimum 200mS Supported Function Codes e IR port 20 and 21 e RS485 and Ethernet ports 1 2 3 4 6 16 17 20 21 Communications Modes of Operation When the Shed Timer is enabled and a write or override occurs the controller will enter Slave Mode The keypad is locked from the operator The purpose of this mode is that if communications is lost and the shed timer times out then the controller will enter a known state of operation The configuration of the Shed Mode and Output and Shed Setpoint Recall are used to configure the controller s shed state While in Slave Mode pushing the MAN AUTO key enters Emergency Manual mode The local operator then has control of the output The controller is in Monitor Mode if the Shed timer is disabled 10 2 Reading Control Data Overview The following control data can be read from this instrument e Input e Input 2 e PV SP Output Register Addresses Use the identifying codes listed in Table 10 1 to read the specific items A Write request for these codes will result in an Error message March 2012 UDC2500 Universal Digital Controller Product Manual 193 Modbus Read Write and Override Parameters plus Exception Codes Table 10 1 Control Data Parameters Parameter Registe
136. ill run until the operator disables it here or until power is turned off and on ATTENTION The instrument does not have to be connected to the external communications link in order to perform this test If it is connected only one instrument should run the loopback test at a time The host computer should not be transmitting on the link while the loopback test is active 76 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration 3 14 Alarms Set Up Group Introduction An alarm is an indication that an event that you have configured for example Process Variable has exceeded one or more alarm limits There are two alarms available Each alarm has two setpoints You can configure each of these two setpoints to alarm on various controller parameters There are two alarm output selections High and Low You can configure each setpoint to alarm either High or Low These are called single alarms You can also configure the two setpoints to alarm on the same event and to alarm both high and low A single adjustable Hysteresis of 0 to 100 is configurable for the alarm setpoint See Table 2 3 in the Installation section for Alarm relay contact information The prompts for the Alarm Outputs appear whether or not the alarm relays are physically present This allows the Alarm status to be shown on the display and or sent via communications to a host computer Function Prompts Table 3 15 ALARMS Gro
137. imal Ca 0080 128 INT R W 0 ON OFF orithm Selection arD A Selection here will 2 PID B affect ID code 160 in 3 PD A with Manual Output Algorithms Reset 4 Three Position Step 5 Disable Timer 00D8 216 INT R W 0 Disable 1 Enable 0063 099 FP R W 00 00 TO 99 59 Start Initiation 00D9 217 INT R W 0 Key Run Hold Key 1 Alarm 2 LDISP Selection OODA 218 INT R W 0 TI REM 1 Elapsed Time Timer Reset 00D6 214 INT R W 0 Key Run Hold Key 1 AL Alarm 1 or Key Timer Increment 00D7 215 INT R W 0 Min Counts hr min 1 Sec Counts min sec March 2012 UDC2500 Universal Digital Controller Product Manual 205 Modbus Read Write and Override Parameters plus Exception Codes 10 7 5 Output Algorithms Table 10 13 lists all the register addresses and ranges or selections for the function parameters in Set up Group Output Parameter Description Output Algorithm Relay Cycle Time Increments Three Position Step Current Range for Current Duplex Current Output Range 206 Table 10 13 Set up Group Output Motor Time for 004B Register Data Data Range or Address Type Enumerated Selection Hex Decimal 00A0 160 INT 0 Time Simplex 1 Not Used 2 Current Simplex 3 Three Position Step or Position Proportioning 4 Time Duplex 5 Current Duplex 6 Current Time Duplex 7 Time Current
138. in this section The following topics are covered in this section 10 1 Overview 192 10 2 Reading Control Data 193 10 3 Read Options Status 194 10 4 Miscellaneous Read Onlys 195 10 5 Setpoints 196 10 6 Using a Computer Setpoint Overriding Controller Setpoint 197 10 7 Configuration Parameters 198 10 8 Modbus RTU Exception Codes 221 General Information 192 Non volatile Memory Retention e This controller uses non volatile memory to store configuration data These memories are guaranteed to retain data for a minimum of ten years as long as the data is not written and erased more than 10 000 times In order not to exceed this number it is strongly recommended that configurations which change rapidly such as Computer Setpoint use the Override feature which does not affect non volatile memory UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes Analog Parameters e Whenever analog register addresses 0001 through 0074 those that can be changed via communications are changed a Write cycle occurs after receipt of the message and the response is returned Override Parameters e Override analog register address 007D computer setpoint is not stored in non volatile memory It can be changed as frequently as desired with no effect on non volatile memory retentivity but the controller must remain in the slave mode Digital Parameters e Whenever d
139. inals See Figure 2 7 Input 1 Terminals See Figure 2 6 Aux Output and Digital Inputs Terminals See Figure 2 17 MI NID ay A JN Communications Terminals See Figure 2 15 and Figure 2 16 22 UDC2500 Universal Digital Controller Product Manual March 2012 Installation ACIDO Line Voltage 79 PROTECTIVE BONDING grounding of this controller and the enclosure in which it is installed shall be in accordance with National and local electrical codes To minimize electrical noise and transients that may adversely affect the system supplementary bonding of the controller enclosure to local ground using a No 12 4 mm copper conductor is recommended Before powering the controller see Prelimnary Checks in this section of the Product Manual Ot is the user s responsibility to provide a switch and non time delay North America quick acting high breaking capacity Type F Europe 1 2A 250V fuse s or circuit breaker for 90 264 Vac applications or 1 A 125 V fuse or circuit breaker for 24 Vac dc applications as part of the installation 3 CAUTION Applying 90 264 Vac to an instrument rated for 24 Vac dc will severely damage the instrument and is a fire and smoke hazard Figure 2 5 Mains Power Supply March 2012 UDC2500 Universal Digital Controller Product Manual 23 Installation Input 1 Thermocouple Use Thermocouple extension wire only Millivolt or Volts exce
140. ing of the first segment by digital input closure NO 9 INHIBIT INTEGRAL RESET Contact closure disables PID Integral Reset action MNFS 10 MANUAL FAILSAFE OUTPUT Controller goes to Manual mode output goes to the Failsafe value ATTENTION This will cause a bump in the output when switching from Automatic to Manual The switch back from Manual to Automatic is bumpless When the switch is closed the output can be adjusted from the keyboard LOCK 11 KEYBOARD LOCKOUT Contact closure disables all keys Lower display shows LOCKED if a key is pressed March 2012 UDC2500 Universal Digital Controller Product Manual 71 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code TIMER Contact closure starts timer if enabled Reopening the switch has no effect INITIATE LIMIT CYCLE TUNING Contact closure starts the slow tuning process The lower display shows DoSLOW Opening the contact has no effect SETPOINT INITIALIZATION Contact closure forces the setpoint to the current PV value Opening the contact has no effect TO REMOTE SETPOINT Contact closure selects the Remote setpoint MANUAL LATCHING Contact closure transition forces the loop to Manual mode Opening the switch has no effect If the M A RESET key is pressed while the switch is closed the loop will return to Automatic mode OUTPUT TRACKS INPUT
141. ing operating Altitude up to 2000m Refernce IEC and ANSI ISA 61010 Pollution Degree Pollution Degree 2 Normally non conductive pollution with occasional conductivity caused by condensation Ref IEC 664 1 EMC Classification Group 1 Class A ISM Equipment EN61326 emissions Industrial Equipment EN61326 immunity Method of EMC Assessment Technical File TF Declaration of Conformity 51453655 Deviation from the installation conditions specified in this manual and the special conditions for CE conformity in Subsection 2 1 may invalidate this product s conformity with the Low Voltage and EMC Directives ATTENTION The emission limits of EN61326 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 meters 98 feet to the antenna e In special cases when highly susceptible apparatus is used in close proximity the user may have to employ additional mitigating measures to further reduce the electromagnetic emissions of this equipment WARNING If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired 6 UDC2500 Universa
142. ion Step test failures For controller configured for Three Position Step Control with motor position indication and Auto cal has never been done the prompt CAL MTR will appear to suggest that the controller be calibrated 7 4 Status Tests Introduction When required the results of these tests can be checked to determine the reason the controller has gone to Failsafe How to check the status tests The procedure in Table 7 2 tells you how to display the results of the status tests Table 7 2 Procedure for Displaying the Status Test Numeric Code 1200 Results Step Operation Press Result 1 Select C setup Upper Display READ STATUS NA Lower Display STATUS Set Up Group 2 Read the test Function You will see results ae Upper Display NO or YES YES indicates a failure Lower Display FAILSAFE Function Upper Display PASS or FAIL Na Lower Display TEST 164 UDC2500 Universal Digital Controller Product Manual March 2012 7 5 Background Tests Introduction Troubleshooting Service The UDC2300 performs ongoing background tests to verify data and memory integrity If there is a malfunction a diagnostic message will be displayed blinking in the lower display In the case of simultaneous malfunctions the messages will appear in sequence in the lower display Table 7 3 lists these background tests the reason for their failure and how to correct the problem Diagnostic messages may be suppressed stop th
143. ions Type as Infrared and your IR address to 3 as shown below in Figure 4 11 Communication ype Infrared z Select Type to setup Lninad Communication Setup Infrared gt Screen helps to setup Infrared parameters Infrared parameters Device Address E Serial Port COM fi Figure 4 11 IR Communications Address UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Close the IR configuration window and then single click on the Online Configuration button shown in Figure 4 12 ZA sic ttt HH Online Configuration Figure 4 12 Online Configuration Press any button on the controller s keyboard to activate the controller s IR port Point your IR dongle if using PC or your Pocket PC s IR port if using Pocket PC at the IR window on the front of the controller and then click on the Start button The P LE Tool should start uploading the configuration information from the controller as shown below Online Configuration tS To terminate Upload click on Abort button Device Type fubca500 vi Upload Status Please wait Upload is in Progress Abort Figure 4 13 Configuration Upload in Progress Once the upload is complete click on the Ethernet amp Email Group Configure your Ethernet and Email parameters per Section 3 16 Once you have changed the Ethernet settings and downloaded
144. ious field calibration done for the output Protect your field calibration from accidental overwrites by configuring the appropriate LOCKOUT selection after calibration See Section 3 Configuration for specific instructions to set the lockout Table 6 5 Restore Factory Calibration Procedure sep operation ress Ree 1 Set LOCKOUT to i until you see NONE NA Upper Display SET Lower Display TUNING YH Until you see Upper Display one of the following NONE all parameters are read write CAL all parameters are read write except Calibration CONF configuration parameters are Read Only no writes permitted VIEW Tuning and Setpoint Ramp parameters are read write No other parameters can be viewed ALL Tuning and Setpoint Ramp parameters are available for read only No other parameters can be viewed Lower Display LOCK ory Until NONE is in the upper display 2 Enter OUTPUT a until you see or OPTIONS N y Upper Display SET Setup Group Lower Display OUTALG for the Current Output or Lower Display OPTION for the Auxiliary Output Function until you see Ne 2 Upper Display the current selection Lower Display CRANGE for the Current Output or Lower Display ARANGE for the Auxiliary Output ory to change the range configuration to the other selection 3 Scroll through Function until the lower display rolls through the rest of the functions and Functions N returns t
145. it otherwise you ll bend or break the tab If you break or bend the tab and can t reattach the front snugly you ll need to reattach the front using the 4 NEMA4 screws provided See Table 2 4 page 17 182 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus RTU Function Codes 9 Modbus RTU Function Codes 9 1 Overview This section describes the function codes needed to upload and download the configuration from a host computer into this instrument What s in this section The following topics are covered in this section 9 1 Overview 183 9 2 General Information 183 9 3 Function Code 20 185 9 4 Function Code 21 189 9 2 General Information This instrument uses a subset of the standard Modbus RTU function codes to provide access to process related information Several MODICON function codes are implemented It is appropriate to define instrument specific user defined function codes Where differences occur between the two protocols it will be noted Several standard Modbus RTU function codes are supported Configuration ID Tags Function codes 20 and 21 use the RS422 485 tag IDs for accessing configuration and process related data These tags are fully explained in Section 10 The tag IDs represent the register addresses used in the Request Message Other Modbus Codes For Modbus codes other than for accessing configuration and process related data for this controller refer to the Modbus RTU Serial
146. ithm The Three Position Step Control algorithm provides an output display OUT which is an estimated motor position since the motor is not using any slidewire feedback Although this output indication is only an approximation it is corrected each time the controller drives the motor to one of its stops 0 or 100 It avoids all the control problems associated with the feedback slidewire wear dirt noise When operating in this algorithm the estimated OUT display is shown to the nearest percent i e no decimal Refer to the Operation section for motor position displays As acustomer configurable option when a second input board is installed the motor slidewire can be connected to the controller March 2012 UDC2500 Universal Digital Controller Product Manual 49 Configuration Function Prompt Selection or Range of Setting Lower Display Upper Display Numeric Numeric Code Code il i DIS 0 TIMER ENAB 1 PERIOD 0 00 to 99 59 Select length of time in Hours and Minutes or minutes and seconds START KEY 0 AL2 1 Parameter Definition The actual slidewire position is then shown on the lower display as POS This value is used for display only It is NOT used in the Three Position Step algorithm To configure this option set Input 2 actuation to SLIDEW Calibrate the slidewire ATTENTION Other prompts affected DEADBD This configuration is usually used for Indicator appli
147. key name will appear in the lower display Refer to Parts Replacement Procedures in this section 174 UDC2500 Universal Digital Controller Product Manual March 2012 Procedure 8 Troubleshooting Service Table 7 11 explains how to troubleshoot a Communications failure Table 7 12 Troubleshooting a RS 485 Communications Failure Step What to do How to do it 1 Check the Address Number See Section 3 13 ComState and Baud Rate settings 2 Check the field wiring and Using an ohm meter check the resistance across termination resistor the communications rear terminals See Section 2 7 for wiring diagrams 3 Make sure the Communications Withdraw the chassis from the case and inspect the Printed Wiring Board is installed board See the exploded view Figure 8 1 for properly in the controller location of the board Return the chassis to the case 4 Determine if the Communications Disconnect the communications cable from the rear board is faulty by running a LOCAL terminals Run the Local Loopback Test LOOPBACK TEST Press SET UP until you see If the test fails replace the board Upper Display If the test passes the problem is most likely elsewhere in the communications network Lower Display COM Press FUNCTION until you see Upper Display Lower Display Press a or V you will see Upper Display Lower Display The test will run until the operator disables it here March 2012 UDC2500 Universal Digital Co
148. l Controller Product Manual 99 Monitoring and Operating the Controller 4 7 Start Up Procedure for Operation Table 4 6 Procedure for Starting Up the Controller Single Dual Operation Press Result Display Display Step Step 1 Configure i Make sure the controller has been configured properly controller NS _ and that all the values and selections have been recorded on the Configuration Record Sheet See steps 4 amp 5 2 Select ALT N A for Single Display Model kanua Beset Until M indicator is ON Mode ni The controller is in manual mode 3 Adjust the N A for Single Display Model Output To adjust the output value and ensure that the final control or element is functioning correctly Upper Display PV Value Lower Display OT and the output value in 4 Select A N A for Single Display Model Automatic Reset AE Mode SA Until A indicator is ON The controller is in Automatic mode The controller will automatically adjust the output to maintain the process variable at setpoint 2 5 Enter the Upper Display Pv Value Local Setpoint Lower Display SP and the Local Setpoint Value A To adjust the local setpoint to the value at which you want i the process variable maintained or The local setpoint cannot be changed if the Setpoint Ramp function is running 3 6 Tune the i Use Accutune to tune the controller see product manual Controller NS for detailed procedure or
149. l Digital Controller Product Manual 123 Monitoring and Operating the Controller Run Monitor the program Prior to running the program make sure all the SP PROG function prompts under the Set Up group SP RAMP have been configured with the required data HOLD appears periodically in the upper display indicating that the program is in the HOLD state ATTENTION in HOLD state Run Monitor functions SP Programmer parameter cannot be changed during RUN state must be Table 4 26 lists all the functions required to run and monitor the program Table 4 26 Run Monitor Functions Set the Local Setpoint Run State Hold State External Hold To Begin Aw or wr 124 UDC2500 Universal Digital Controller Product Manual Upper Display PV value Lower Display SP To set the Local Setpoint value to where you want the program to start out Initiates the setpoint program RUN appears in the upper display indicating that the program is running Holds the setpoint program HOLD appears in the upper display indicating that the program is in the HOLD state The setpoint holds at the current setpoint If one of the Digital Inputs is programmed for the HOLD function then contact closure places the controller in the HOLD state if the setpoint program is running The upper display will periodically show HOLD while the switch is closed ATTENTION The keyboard takes
150. l Digital Controller Product Manual March 2012 Installation 2 Installation 2 1 Overview Introduction Installation of the UDC2500 consists of mounting and wiring the controller according to the instructions given in this section Read the pre installation information check the model number interpretation Subsection 2 3 and become familiar with your model selections then proceed with installation What s in this section The following topics are covered in this section TOPIC See Page 2 1 Overview 2 2 Condensed Specifications 2 3 Model Number Interpretation 2 4 Control and Alarm Relay Contact Information 15 2 5 Mounting 16 2 6 Wiring 18 2 7 Wiring Diagrams Composite Wiring Diagram AC Line Voltage Input 1 Connections Input 2 Connections Relay Output Electromechanical Solid State Open Collector Dual Electromechanical Relay Current Output Connections Three Position Step Control Connections w o Dual Relay Three Position Step Control Connections with Dual Relay RS 422 485 Communications Option Ethernet Communications Option Auxiliary Output and Digital Inputs Option Transmitter Power using Open Collector Output Transmitter Power using Auxiliary Output March 2012 UDC2500 Universal Digital Controller Product Manual 7 Installation Pre installation Information If the controller has not been removed from its shipping carton inspect the carton for damage then remove the controller e Inspect the unit for
151. lay DIS Upper RESTORE Lower 5 Press the 4 key The instrument will now display CFG Upper RESTORE Lower 6 Press the 4 key The instrument will now display OPTN Upper RESTORE Lower 7 Press the FUNCTION Key The instrument will now display XXXX Upper ENTER Lower where XXXX is a unique code number for this particular instrument Write this number down 8 Press the FUNCTION Key The instrument will now display XXXX ENTER2 Write this number down 9 Press the FUNCTION Key The instrument will now display XXXX ENTERS Write this number down 10 Write down the Model and Serial Numbers of your instrument 178 UDC2500 Universal Digital Controller Product Manual March 2012 11 12 13 14 15 16 17 Troubleshooting Service Contact your Honeywell Representative to place an order Please have a company purchase order number available before you call The order entry person will ask for the following information 1 Software Upgrade Part Number you require Dual Display with Auto Manual 50004634 501 or Set Point Programming includes Dual Display and Auto Manual 50004634 502 Model Number of your instrument s Serial Number of your instrument s Code Numbers 1 2 and 3 from your instrument s Purchase order number oo o yN With this information a new code number set will be generated for your instrument When you ha
152. ler Load EM 4 20 mA 0 1000 ohms Load o Relay Load Load Supply z 4 Power o 4 e ES ee A Load o Supply Power o To terminal 70r9 When the instrument has the Current Output as shown no Alarms are available when using the Time Proportional Duplex or Three Position Step Control Output Algorithms as these outputs require both available relays Electromechanical relays are rated at 5 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Relay Load Figure 2 12 Current Output See Table 2 6 for relay terminal connections for other Output Algorithm Types 28 UDC2500 Universal Digital Controller Product Manual March 2012 Installation Open CW O Alarm 2 is not available with this configuration 2 Electromechanical Relays are rated at 5 amps at 120 Vac or 240 Vac or 24 Vdc Solid State Relays are rated at 1 Amp at 25 C and derated linearly to 0 5 Amps at 55 C Customer should size fuses accordingly Use Fast Blo fuses only Figure 2 13 Three Position Step Control Connections w o Dual Relay Option Close CCW pa 19 Control 20 Relay 2 5321 Control Relay 1 L1 Hot Q Alarm 2 is available with with this configuration Dual Electromechanical relays are rated at 2 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Figure 2 14 Three Position Step Cont
153. ll documents that may be sources of reference for material discussed in this publication Document Title Process Instrument Explorer manual How to Apply Digital Instrumentation in Severe Electrical Noise Environments Modbus RTU Serial Communications User Manual MODBUS Messaging on TCP IP Implementation Guide 51 52 25 131 51 52 05 01 51 52 25 66 51 52 25 121 March 2012 UDC2500 Universal Digital Controller Product Manual Introduction Support and Contact info United States and Canada Contact Honeywell Process Solution Global Technical Support Phone 001 800 423 9883 Customer Service HFS Phone 001 800 343 0228 Outside United States Phone 001 215 641 3610 Calls are answered by dispatcher between 6 00 am and 4 00 pm Mountain Standard Time Emergency calls outside normal working hours are received by an answering service and returned within one hour Email support ask ssc O honeywell com Mail Honeywell Process Solutions 1860 West Rose Garden Lane Phoenix Arizona 85027 For more contact details for Europe Asia North and South Americas please see back page World Wide Web Honeywell Process Solutions Support Online www honeywellprocess com Elsewhere Call your nearest Honeywell office Training Classes Honeywell Automation College http www automationcollege com iv UDC2500 Universal Digital Controller Product Manual March 2012 Introduction Symbol Definitions Th
154. ller are stored in its non volatile memory Thus you can quickly restore the Factory Calibration for a given input actuation type by simply changing the actuation type to another type and then changing it back to the original type Refer to Table 5 14 Restore Factory Calibration for procedure ATTENTION A restored factory calibration overwrites any previous field calibration done for the input and may change the High and Low Range Limits Protect your field calibration from accidental overwrites by configuring the appropriate LOCKOUT selection after calibration See Section 3 Configuration for specific instructions to set the lockout Table 5 14 Restore Factory Calibration CIC Pes eoo OO y 1 Set LOCKOUT to coe until you see NONE NS Upper Display SET UP Lower Display TUNING HY Until you see Upper Display one of the following NONE all parameters are read write CAL all parameters are read write except Calibration CONF configuration parameters are Read Only no writes permitted VIEW Tuning and Setpoint Ramp parameters are read write No other parameters can be viewed ALL Tuning and Setpoint Ramp parameters are available for read only No other parameters can be viewed Lower Display LOCK ory Until NONE is in the upper display 2 Enter INPUT 1 i until you see Setup Group gt E ee a INPUT 1 or 2 Function et Display the current selection Lower Display INxTYP Mor ww to chang
155. ls there are no internal jumpers or switches to change This flexibility allows a customer to stock a single instrument which is able to handle a variety of applications Table 2 6 shows what control types and alarms are available based upon the installed outputs In this table when Duplex Control and Reverse Action are configured Output 1 is HEAT and Output 2 is COOL In Table 2 6 when Three Position Step Control is configured Output 1 is OPEN and Output 2 is CLOSE In Table 2 6 the Output 1 2 option Single Relay can be any of the following selections Electro Mechanical Relay Solid State Relay or Open Collector Output 20 UDC2500 Universal Digital Controller Product Manual March 2012 Installation Table 2 6 Universal Output Functionality and Restrictions Output Algorithm Output 1 2 Function of Output 1 2 Output 3_ Output 4_ Auxiliary Output _ Time Simplex Single Relay Current Output Dual Relay Time Duplex or ree Current Output Dual Relay Outputs 1 and Not Needed 2 Current Simplex Current Dup 100 Single Relay NU Alarm2 Alarm Outputs 1 and2_ Current COOL Current Output Sas 1 and Alarm 2 Alarm 1 Not Needed and HEAT Dual Relay Current Duplex ETA NRO 50 Aux Out COOL Current Time Current COOL Time HEAT Time Current Time COOL Current HEAT TPSC Three Position Step Control N A Not Available This output algorithm type cannot be performed with this Output 1 2 op
156. lts 0 to 5 Volts or 1 to 5 Volts Input 2 Table 5 13 Input 2 Calibration Procedure Numeric Code 20000 Table 5 14 Restore Factory Calibration Table 6 1 Set Up Wiring Procedure for Current Output Table 6 2 Current Output Calibration Procedure Numeric Code 30000 Table 6 3 Set Up Wiring Procedure for Auxiliary Output Table 6 4 Auxiliary Output Calibration Procedure Numeric Code 50000 Table 6 5 Restore Factory Calibration Procedure Table 7 1 Procedure for Identifying the Software Version Table 7 2 Procedure for Displaying the Status Test Numeric Code 1200 Results Table 7 3 Background Tests Table 7 4 Controller Failure Symptoms Table 7 5 Troubleshooting Power Failure Symptoms Table 7 6 Troubleshooting Current Output Failure Table 7 7 Troubleshooting Three Position Step Control Output Failure Table 7 8 Troubleshooting Time Proportional Output Failure Table 7 9 Troubleshooting Current Time or Time Current Proportional Output Failure Table 7 10 Troubleshooting Alarm Relay Output Failure Table 7 11 Troubleshooting a Keyboard Failure Table 7 12 Troubleshooting a RS 485 Communications Failure Table 7 13 Troubleshooting an Ethernet Communications Failure Table 7 14 Troubleshooting Auxiliary Output Failure Table 7 15 Restoring Factory Configuration Table 7 16 Software Upgrades Table 8 1 Parts Identification Table 8 2 Parts Not Shown Table 8 3 Software Upgrades see Section 7 9 Table 9 1 Integer Parameter Type Table 9 2 Floatin
157. me 9 0 Recycles SOKDEV Deviation 0 SG10SP Soak SP 10 400 Value SG1RP_ Ramp Time 1 1 hr SG10 TI Soak Time 10 0 hr 30 min SG2SP Soak SP 2 300 SG11 RP Ramp Time 11 3 hr 30 min SG2 TI Soak Time 2 1 hr 30 min SG12 SP Soak SP 12 200 SG3RP Ramp Time 3 1 hr SG12TI Soak Time 12 0 hr 30 min SG4SP Soak SP 4 400 122 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Program record sheet Draw your ramp soak profile on the record sheet shown in Figure 4 4 and fill in the associated information in the blocks provided This will give you a permanent record of your program and will assist you when entering the Setpoint data Figure 4 4 Program Record Sheet STRSEG Start Seg SG4 TI Soak Time 4 ENDSEG End Seg SG5 RP Ramp Time 5 RP UNIT Engr Unit for SG6SP Soak SP 6 Ramp RECYCL Number of SEG6 TI Soak Time 6 Recycles SOKDEV Deviation Value SG7 RP Ramp Time 7 PGEND Controller SG8SP Soak SP 8 Status STATE Program SG8 TI Soak Time 8 Controller State TO BEGIN Reset SP SG9RP Ramp Time 9 Program PVSTRT Program starts SG10SP Soak SP 10 at PV value SG1RP Ramp Time 1 SG10 TI Soak Time 10 SG2SP Soak SP 2 SG11RP Ramp Time 11 SG2 TI Soak Time 2 SG12SP Soak SP 12 SG3RP Ramp Time 3 SG12TI Soak Time 12 SG4SP Soak SP 4 March 2012 UDC2500 Universa
158. mer is enabled because Alarm 1 is dedicated to Timer output NOTE 3 This Deviation Alarm is based upon deviation from the 2nd Local Setpoint or Remote SP regardless of whichever SP is active NOTE 4 Loop Break monitors the control loop to determine if it is working When enabled the control output is checked against the minimum and maximum output limit settings When the output reaches one of these limits a timer begins If the timer expires and the output has not caused the PV to move by a pre determined amount then the alarm activates thus signalling that the loop is broken The loop break timer value must be configured by the operator as the AxSx VAL entry This value is in seconds with a range of 0 to 3600 seconds A setting of 0 is equivalent to an instantaneous loop break when the output reaches one of its limit values The amount of PV Movement required is determined by the UNITS setting in the Display Setup Group For the Degrees F configuration the PV must move by 3 in the desired direction in the time allowed For the Degrees C configuration the PV must move by 2 in the desired direction in the time allowed For the NONE selection the PV must move 1 of the PV range in the time allowed Loop Break alarms do not have a HIGH LOW State configuration they are always assumed to be a HIGH state alarm 78 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration
159. meter Register Data Access Data Range or Enumerated Selection Description Address Type Hex Decimal Input 1 00A9 Transmitter Characterization 169 INT 0 B TC 1 ETCH 2 ETCL 3 JTCH 4 JTCM 5 JTCL 6 KTCH 7 KTCM 8 KTCL 9 NNMH 10 NNM L 11 Nicrosil H TC 12 Nicrosil L TC 13 R TC 14 S TC 15 T TC H 16 T TC L 17 W TC H 18 W TC L 19 100 PT RTD 20 100 PT LO RTD 21 200 PT RTD 22 500 PT RTD 23 Radiamatic RH 24 Radiamatic RI 25 Linear 26 Square Root Input 1 High 001D Range Value 029 FP 999 to 9999 Engineering Units Linear types only Input 1 Low 001E Range Value 030 FP 999 to 9999 Engineering Units Linear types only Input 1 Ratio 006A 106 FP 20 00 to 20 00 Input 1 Bias 006B 107 FP 999 to 9999 Engineering Units Input 1 Filter 002A 042 FP 0 to 120 seconds 208 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Burnout Open OOA4 164 INT R W 0 None and Failsafe Circuit 1 Upscale Detection 2 Downscale 3 No Failsafe Emissivity 0017 023 FP R W 0 01 to 1 00 March 2012 UDC2500 Universal Digital Controller Product Manual 209 M
160. minal Provided for connection of the protective earth green or green yellow supply system conductor Functional earth terminal Used for non safety purposes such as noise immunity improvement NOTE This connection shall be bonded to Protective Earth at the source of supply in accordance with national local electrical code requirements Earth Ground Functional earth connection NOTE This connection shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements Chassis Ground Identifies a connection to the chassis or frame of the equipment shall be bonded to Protective Earth at the source of supply in accordance with national and local electrical code requirements March 2012 UDC2500 Universal Digital Controller Product Manual v Introduction vi Description The Canadian Standards mark means the equipment has been tested and meets applicable standards for safety and or performance For radio equipment used in the European Union in accordance with the R amp TTE Directive the CE Mark and the notified body NB identification number is used when the NB is involved in the conformity assessment procedure The alert sign must be used when a restriction on use output power limit by a country at certain frequencies applies to the equipment and must follow the CE marking UDC2500 Universal Digital Controller Product Manual March 2012 Introdu
161. n Prompt Selection or Range of Setting Lower Display Upper Display Numeric Numeric Code Code 2 DOWN 0 01 to 1 00 Configuration Parameter Definition DOWNSCALE BURNOUT will force the Input 1 signal to the lower range value when the sensor fails Diagnostic message IN1 FAIL intermittently flashed on the lower display The controller remains in Automatic control mode and adjusts the controller output signal in response to the lower range Input 1 signal developed by the Burnout circuitry This selection does not provide input failure detection and should only be used when a thermocouple input is connected to another instrument which supplies the Burnout current For this selection no burnout signal is sent to the sensor when a thermocouple input is connected to another instrument which supplies the Burnout current For this selection no burnout signal is sent to the sensor ATTENTION For Burnout to function properly on a 0 20 mA input type or a 0 5V type that uses a dropping resistor the dropping resistor must be remotely located across the transmitter terminals Otherwise the input at the UDC terminals will always be O mA i e within the normal operating range when the 0 20 mA line is opened EMISSIVITY is a correction factor applied to the Radiamatic input signal that is the ratio of the actual energy emitted from the target to the energy which would be emitted if the target were a perfect r
162. nction Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code However keep in mind that relay output 100 PCT Value in Engineering Units types can only be scaled 0 to 100 CRANGE 4 20 AUXILIARY OUTPUT RANGE allows the 0 20 user to easily select 4 20mA output or 0 y 20mA output operation without the need for recalibration of the instrument ATTENTION Changing the Auxiliary Output Range will result in the loss of Field Calibration values and will restore Factory Calibration values DIGIN1 905 DIGITAL INPUT 1 SELECTIONS AI selections are available for Input 1 The controller returns to its original state when contact opens except when overruled by the AUXILIARY OUTPUT HIGH SCALING FACTOR This is a value in engineering units used to represent all AUX OUT parameters except Output For Output this is a value in percent and can be any value between 5 and 105 keyboard NONE 0 NO DIGITAL INPUT SELECTIONS MAN 1 TO MANUAL Contact closure puts the affected loop into manual mode Contact open returns controller to former mode LSP 2 TO LOCAL SETPOINT When a remote setpoint is configured contact closure puts the controller into local setpoint 1 When contact opens the controller returns to former operation local or remote setpoint unless SETPOINT SELECT key is pressed while digital input is active If this happens the contr
163. neering Range Value Units Input 2 Low 0024 036 FP R W 999 to 9999 Engineering Range Value Units Input 2 Ratio 0025 037 FP R W 20 00 to 20 00 Input 2 Bias 0026 038 FP R W 999 to 9999 Engineering Units Input 2 Filter 002B 043 FP R W 0 to 120 seconds March 2012 UDC2500 Universal Digital Controller Product Manual 211 Modbus Read Write and Override Parameters plus Exception Codes 10 7 8 Control Table 10 16 lists all the register addresses and ranges or selections for the function prompts in Set up Group Control Table 10 16 Set up Group Control Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Tuning OOAC 172 INT R W 0 One set only Parameter 1 2 sets keyboard selected Selection 2 2 sets with PV automatic switchover 3 2 sets with setpoint SP automatic switchover Automatic 0038 056 FP R W Within the PV Range in Switchover engineering units Value used with 172 selection 2 or 3 Local Setpoint OOAD 173 INT R W 0 One Local Setpoint Source Number 1 Two Local Setpoints of LSPs Power Up Mode 0082 130 INT R W Control Setpoint Recall Mode Mode 0 MAN LSP 1 AUTO LSP 2 AUTO Last RSP 3 LAST Last SP 4 LAST Last Local SP RSP Source 0083 131 INT R W 0 None 1 Input 2 Setpoint 008A 138 INT R W 0 None Tracking 1 LSP PV when in Manual 2 LSP RSP when switched
164. ng constants for your control loop When initiated on demand the Accutune algorithm measures a process step response and automatically generates the PID tuning constants needed for no overshoot on your process Fuzzy Fuzzy Overshoot Suppression When enabled this configuration will suppress or eliminate any overshoot that may occur as a result of the existing tuning parameters as the PV approaches the setpoint Tune Demand Tuning The tuning process is initiated through the operator interface keys or via a digital input if configured The algorithm then calculates new tuning parameters and enters them in the tuning group Tune will operate with PIDA PIDB PD MR and Three Position Step Control algorithms SP SP Tuning SP tuning continuously adjusts the PID parameters in response to setpoint changes You can select tuning on minimum setpoint changes of 5 up to 15 span Perform SP tuning after you have configured the controller SP Tuning does not operate with the Three Position Step Control algorithm Simplex Tuning is used when a Simplex Control Algorithm is configured and uses the current SP value and alters the output over the Output Limit Range Duplex Tuning is used when a Duplex Control Algorithm is configured To perform a Duplex Tune Two Local Setpoints must be configured per the Control Group in Section 3 11 UDC2500 Universal Digital Controller Product Manual March 2012 Function Prompts Configuration Table 3 6 A
165. ng units ATTENTION The control setpoint will be limited by the range of units selected here 20 0 to 20 0 RATIO ON INPUT 1 Select the Ratio value you want on Input 1 RATIO1 some other cause Select the bias value you want on Input 1 999 to 9999 BIAS ON INPUT 1 Bias is used to compensate the input for drift of an input value due to deterioration of a sensor or FILTR1 607 0 to 120 seconds 0 No Filter FILTER FOR INPUT 1 A software digital filter is provided for Input 1 to smooth the input signal You can configure the first order lag time constant from 1 to 120 seconds If you do not want filtering enter 0 BURNOUT PROTECTION SENSOR BRNOUT 608 BREAK provides most input types with upscale or downscale protection if the input fails NONE NO BURNOUT Pre configured Failsafe output selected in the CONTROL Set up Group applied if failed input is detected does not apply for an input out of range Diagnostic message IN1 FAIL is intermittently flashed on the lower display UP UPSCALE BURNOUT will force the Input 1 signal to the full scale value when the sensor fails Diagnostic message IN1 FAIL intermittently flashed on the lower display The controller remains in Automatic control mode and adjusts the controller output signal in response to the full scale Input 1 signal developed by the Burnout circuitry 58 UDC2500 Universal Digital Controller Product Manual March 2012 Functio
166. ning the Software Version Number 1 3 Power up Tests 7 4 Status Tests 7 5 Background Tests 7 6 Controller Failure Symptoms 7 7 Troubleshooting Procedures 168 e Power Failure e Current Proportional Output Failure e Time Proportional Output Failure e Time Current Current Time Proportional Output Failure e Alarm Relay Output Failure e Keyboard Failure 7 8 Restore Factory Configuration 7 9 Software Upgrades March 2012 UDC2500 Universal Digital Controller Product Manual 161 Troubleshooting Service Installation related problems Read the Installation section in this manual to make sure the UDC2500 has been properly installed The installation section provides information on protection against electrical noise connecting external equipment to the controller and shielding and routing external wiring ATTENTION System noise induced into the controller will result in diagnostic error messages recurring If the diagnostic error messages can be cleared it indicates a soft failure and is probably noise related If system noise is suspected completely isolate the controller from all field wiring Use calibration sources to simulate PV and check all controller functions i e Gain Rate Reset Output Alarms etc Application related problems Review the application of the controller then if necessary direct your questions to the local sales office Hardware and software related problems Use the troubles
167. ns link and return to stand alone operation You can also set the SHED output mode and setpoint recall and communication units Up to 99 addresses can be configured over this link The number of units that can be configured depends on the link length with 31 being the maximum for short link lengths and 15 drops being the maximum at the maximum link length Function Prompts Table 3 14 Communications Group Numeric Code 1000 Function Prompts Function Prompt Selection or Range of Parameter Lower Display Setting Definition Upper Display Numeric Numeric Code Code ComADR COMMUNICATIONS STATION ADDRESS This is a number that is assigned to a controller that is to be used with the communications option This number will be its address This parameter is also used for the IR communications link COMMUNICATIONS SELECTION DISABLE Disables the communications option MODBUS Enable Modbus RTU communications ETHERNET Enable Ethernet Communications BAUD RATE is the transmission speed in bits per second This value is used for both RS 485 and IR Communications but for IR Communications values below 19200 baud are interpreted as being 19200 baud 4800 BAUD 9600 BAUD 19200 BAUD 38400 BAUD IRENAB INFRARED COMMUNICATIONS Enables Disables the IR Port BAUD 74 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Parameter Definition Lower Display S
168. nt Off 9 Manual 10 Remote Setpoint 11 Failsafe 12 PV Rate of Change 13 Alarm on Digital Input 1 14 Alarm on Digital Input 2 15 Loop Break 16 Deviation based upon SP2 17 T C Warning 18 T C Fail March 2012 UDC2500 Universal Digital Controller Product Manual 217 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Description Address Hex Decimal Alarm 1 Setpoint 2 008E Type 142 Data Type INT Access Data Range or Enumerated Selection Same as 140 144 INT Same as 140 Alarm 2 Setpoint 1 0090 Type Alarm 2 Setpoint 2 0092 Type 146 INT Same as 140 141 INT 0 Low Alarm 1 High Alarm Alarm 1 Setpoint 1 008D Event Alarm 1 Setpoint 2 0OSF Event 143 INT 0 Low Alarm 1 High Alarm Alarm 2 Setpoint 1 0091 Event 145 INT 0 Low Alarm 1 High Alarm Alarm 2 Setpoint 2 0093 Event 147 INT 0 Low Alarm 1 High Alarm Alarm Hysteresis 0029 041 FP 0 0 to 100 of output or span Alarm Latching for 00C8 Output 1 200 INT 0 Non Latching 1 Latching Alarm States 00C9 201 INT State 0 Not in Alarm State 1 In Alarm Bit 0 Alarm 11 State Bit 1 Alarm 12 State Bit 2 Alarm 21 State Bit 3 Alarm 22 State Event 0 Low Event 1 High Bit 4 Alarm 11 Event
169. ntenance Data menu Maintenance Data Ethernet Status The Status Data screen lets you see the current status of the controller s diagnostics If the controller has detected a problem this screen will show the detected problem Maintenance Status Data gt Screen refreshes automatically if the communication link is selected as RS485 or Ethernet Tool provides manual refresh if a communication link is selected as Infrared RAM CFG Memory Cal Memory Fact Memory Fail Safel Fail Safe2 TC Inpl Device Type Figure 4 9 Status Data Maintenance Screen 130 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Ethernet Status Select Ethernet Status from the Maintenance Data menu Maintenance Data Loop Data Status Data This screen only appears in instruments that have the Ethernet Communications option Essentially this screen shows the same Ethernet diagnostic messages as available on the controller via the lower display window See Section 7 5 for details The Ethernet Status screen shows the network status of the Ethernet Link This may be accessed either via Ethernet or via Infrared communications Not all diagnostic messages are available via Ethernet Communications For example if the Ethernet cable is unplugged then the instrument cannot send up the EUNPLGED diagnostic message via Ethernet Maintenance Ethernet Status Da
170. ntil the A indicator is lighted on controllers with Manual option Until NoTUNE is shown on lower display Select DoSLOW or DoF AST in lower display Upper display will flash TUNE as long as ACCUTUNE process is operating When process completes tuning parameters are calculated and lower display will show NoTune prompt 4 11 5 Using MANUAL TUNE at start up for Duplex Heat Cool When DUPLEX has been configured for MANUAL This selection should be used when tuning is needed only for the HEAT zone or only for the COOL zone but not both If Local Setpoint 1 is used then the controller will perform a HEAT zone tune If Local Setpoint 2 is used then the controller will perform a COOL zone tune Table 4 14 Procedure for Using MANUAL TUNE for Heat side of Duplex Control sp Operation press re 1 Configure LSP1 2 3 Switch to Automatic Mode 4 Show Tuning Prompt Until SP Local Setpoint 1 shows in the lower display Until LSP1 is a value within the Heat Zone output above 50 Until the A indicator is lighted on controllers with Manual option Until NoTUNE is shown on lower display 108 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller sp Operation press re 5 Initiate Tuning Tuning in operation Select DoSLOW or DoF AST in lower display Upper display will fl
171. ntroller Product Manual 175 Troubleshooting Service Procedure 9 Table 7 13 explains how to troubleshoot a Communications failure Table 7 13 Troubleshooting an Ethernet Communications Failure Step What to do How to do it 1 Check the IP address Subnet See the PIE Tool Manual Mask address and Gateway address settings 2 Check if the Ethernet Connection Looking into the instrument there should be steady is active green LED If this is not present then the instrument is not seeing a valid Ethernet connection See Section 2 7 for wiring diagrams A second green LED will blink during actual Ethernet transactions 3 Change Ethernet Installation instructions provided with new Communications board board 4 Change Controller Procedure 10 Table 7 14 explains how to troubleshoot Auxiliary Proportional Output failure symptoms Table 7 14 Troubleshooting Auxiliary Output Failure Step What to do How to do it 1 Make sure the controller is Make Options Set Up group function prompt configured for Auxiliary Output AUX OUT any selection other than NONE If and the proper range 4 to 20 or this prompt does not show up check if DIG IN 0 to 20 is configured 2 is enabled If so then as Auxiliary Ouptut and Digital Input 2 are mutually exclusive you must chose which one of these features you wish to use Make the Options Set UP group function prompt CRANGE 4 20 or 0 20 per your application Refer to Section 3 Configu
172. nts and enters them into the Tuning group and begins PID control with the correct tuning parameters This works with any process including integrating type processes and allows retuning at a fixed setpoint 4 11 1 Tune for Simplex Outputs After TUNE has been enabled you can start Accutune as shown in Table 4 11 Table 4 11 Procedure for Starting TUNE sp Operation Press re 1 Configure LSP1 Until SP Local Setpoint 1 shows in the lower display 2 Until LSP1 is to the desired value 3 Switch to Until the A indicator is lighted on Automatic Mode controllers with Manual option 4 Show Tuning Until No TUNE is shown on lower Prompt display 5 Initiate Tuning Select DoSLOW or DoF AST in lower display 6 Tuning in operation Upper display will flash TUNE as long as ACCUTUNE process is operating When process completes tuning parameters are calculated and lower display will show NoTune prompt ATTENTION The Accutune process may be aborted at any time by changing the lower display back to NoTUNE or by switching the controller into Manual Mode 4 11 2 Tune for Duplex Heat Cool 106 Accutune for applications using Duplex Heat Cool control The controller must be configured to have two local setpoints unless Blended Tuning is desired see below See Subsection 3 11 Control Set Up Group for details on configuring two local setpoints During tuning the Ac
173. nual March 2012 Output Calibration Procedure The procedure for calibrating the Current Output is listed in Table 6 2 The numeric codes are also listed Make sure LOCK in the Tuning Set Up group is set to NONE See Subsection 3 4 Tuning Set Up Group Table 6 2 Current Output Calibration Procedure Numeric Code 30000 CCT mes A 1 Enter Calibration A Upper Display CAL Mode NUE Lower Display CURENT 30000 until you see 2 Calibrate 0 Function You will see m Upper Display A Value Lower Display ZROVAL 30001 Axorw Until the desired 0 output is read on the milliammeter use the values shown below depending on the action of your controller Normally this will be the setting that produces 4 mA 3 Calibrate 100 Function This stores the 0 value and NE you will see Upper Display A Value Lower Display SPNVAL 30002 A ory Until the desired 100 output is read on the milliammeter use the values shown below depending on the action of your controller Normally this will be the setting that produces 20 mA 4 Exit the Calibration Mode The controller stores the span value To exit the calibration mode March 2012 UDC2500 Universal Digital Controller Product Manual 155 6 3 Auxiliary Output Calibration Introduction Calibrate the controller so that the auxiliary output provides the proper amount of current over the desired range The controller can provide an auxiliary c
174. o March 2012 UDC2500 Universal Digital Controller Product Manual 159 Output Calibration sep operon pees Pee Upper Display the new selection Lower Display CRANGE for the Current Output or Lower Display ARANGE for the Auxiliary Output AX orw to change the range selection in the upper display back to the proper selection You will see Upper Display Original range selection Lower Display CRANGE for the Current Output or Lower Display ARANGE for the Auxiliary Output 4 Return to Normal Pana to return to Normal operating mode Operation ba The factory calibration will be restored If the problem is not corrected contact the Honeywell Technical Assistance Center at 1 800 423 9883 USA and Canada 160 UDC2500 Universal Digital Controller Product Manual March 2012 Troubleshooting Service 7 Troubleshooting Service 7 1 Overview Introduction Instrument performance can be adversely affected by installation and application problems as well as by hardware problems We recommend that you investigate the problems in the following order e installation related problems e application related problems e hardware and software related problems and use the information presented in this section to solve them What s in this section The following topics are covered in this section 7 2 Troubleshooting Aids e Overall Error Messages e Controller Failure Symptoms e Customer Support e Determi
175. odbus Read Write and Override Parameters plus Exception Codes 10 7 7 Input 2 Table 10 15 lists all the register addresses and ranges or selections for the function parameters in Set up Group Input 2 Table 10 15 Set up Group Input 2 Parameter R Description A egister Data Access Data Range or ddress Type Enumerated Selection Hex Decimal OOAA Input 2 Type 170 INT R W 0 Disable 1 to 25 Unused 26 0 20 mA 27 4 20 mA 28 to 30 Unused 31 0 5 Vdc 32 1 5 Vdc 33 Unused 34 Unused 35 0 2 Vdc ATTENTION Changing the Input Type will result in the loss of Field Calibration values and will restore the Factory Calibration values 210 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Input 2 OOAB 171 INT R W 0 B TC Transmitter 1 ETCH Characterization 2 ETCL 3 JTCH 4 JTCM 5 JTCL 6 KTCH 7 KTCM 8 KTCL 9 NNMH 10 NNM L 11 Nicrosil H TC 12 Nicrosil L TC 13 R TC 14 S TC 15 T TC H 16 T TC L 17 W TC H 18 W TC L 19 100 PT RTD 20 100 PT LO RTD 21 200 PT RTD 22 500 PT RTD 23 Radiamatic RH 24 Radiamatic RI 25 Linear 26 Square Root Input 2 High 0023 035 FP R W 999 to 9999 Engi
176. ode 50 CURRENT DUPLEX RANGE SPLIT This setting should be used for Relay Current and Current Relay Duplex Outputs It can also be used for Current Duplex when an Auxiliary Output board is present This enables the normal control current output to provide heat control and the auxiliary current output to provide cool control To enable this e AUX OUT in the Options Set Up group must be selected for Output The Auxiliary Current Output is scaled as desired for 0 50 controller output Deadband for this configuration only applies to the Current Output The Auxiliary Output must have the Deadband scaled in FOR EXAMPLE If a2 Deadband is desired then enter 2 0 for the Deadband selection in the Control Algorithm group This will apply Deadband to the Current Output In the Options group set the Auxiliary Output LOW VAL selection to 49 0 and the HIGH VAL selection to 0 0 CURRENT DUPLEX RANGE FULL enables the Current Output to provide both heat and cool functions for control over 0 100 of the controller output The PID heat parameters apply when the output is greater than 50 and the PID cool parameters apply when the output is less than 50 The second current output is not required for this type of duplex operation 54 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric
177. ode FINLSP Enter a value within the setpoint limits Selection or Range of Setting Upper Display Numeric Code Configuration Parameter Definition SETPOINT RAMP FINAL SETPOINT Enter the value desired for the final setpoint The controller will operate at the setpoint set here when ramp is ended ATTENTION If the ramp is on HOLD the held setpoint can be changed by the a and Y keys However the ramp time remaining and original ramp rate is not changed Therefore when returning to RUN mode the setpoint will ramp at the same rate as previous to the local setpoint change and will stop if the final setpoint is reached before the time expires If the time expires before the final setpoint is reached it will jump to the final setpoint ATTENTION SP RAMP and SP RATE will cause the SP portion of Accutune to abort PV Tune will continue to function normally Ramp is placed into HOLD while tuning TUNE configuration SPRATE SP Rate operates only when neither SP Ramp or SP Programming is running or when SP Ramp and SP Programming are disabled 0 to 9999 in Engineering units per hour March 2012 0 1 UDC2500 Universal Digital Controller Product Manual SETPOINT RATE Lets you configure a specific rate of change for any local setpoint change DISABLE SETPOINT RATE Disables the setpoint rate option ENABLE SETPOINT RATE Allows the SP rate feature RATE UP Rate up v
178. odes iis seni testis acti TAI A etna ent al ena Late a 101 48 1 Mode Definitions sitial sath loctsbediguslabeceds Hlacceetoebeleetageciessizbeles 101 4 8 2 What happens when you change MoOdeS coocconncnnncnnnconoonnooncnoncnnncnonononononocnn ccoo nono nccnnccnnacnns 102 AQ Seton nonen cht ies cacoakt Math ER atid tiered ia cameo ee aaa ee eset 102 RE 103 4 11 Acc tune Mk conan start een a ER E eeN a aeta eer Ka iE ta 105 4 11 1 Tune tor Simplex OUtpUtS unir rt liada 106 4 11 2 Tune for Duplex Heat Cool iii cone E aa EETA A EERE AEE EEEE 106 4 11 3 Using AUTOMATIC TUNE at start up for Duplex Heat Co0b oonconccninnnnoconoccnanoos 107 4 11 4 Using BLENDED TUNE at start up for Duplex Heat Cool oooonccinccnnccnoccnocnconcconacnn 107 4 11 5 Using MANUAL TUNE at start up for Duplex Heat Cool seeen 108 4 11 6 Error Codes iii el eater e avin a ceed il pied sng ce eee ee 110 4 12 Fuzzy Overshoot Suppression insiren a aa aa o e aa 111 4 13 Using Two Sets of Tuning Constant 200 0 ccc cecccccesseeesseceeaeceeeeeceeeessaeceseaeeceeeeeaeceeaeeceeeeeesas 111 4TA lt cAlarm Setpomts iia li 113 4 15 Three Position Step Control AlgorithM oonnccnncnnnnnncnnncnnocnnonnnncnonncnnncnn nono nc cono noneconccnnncnnnannss 114 4 16 Setting a Failsafe Output Value for Restart After a Power Loss oooonncnnncnnoccnocononcconaconaconccnnos 115 4A7 Setting Failsafe Modeschoenen eaa ee aee OE E E N Ra iaer Eea 116 4 18 Setpoint Rate Ramp Program
179. oint Code Selections 193 Setpoint High Limit 64 Setpoint Low Limit 64 Setpoint Ramp 39 Setpoint Ramp 116 Setpoint Ramp Final Setpoint 40 Setpoint Ramp Time 39 Setpoint Ramp Soak Programming 118 Setpoint Rate 40 Setpoint Rate 117 Setpoint Select Key Lockout 38 Setpoint Tracking 63 Setpoints 101 193 Set Up Group Accutune 201 Set Up Group Alarms 214 Set Up Group Algorithm 202 Set Up Group Communications 213 Set Up Group Control 209 Set Up Group Display 217 Set Up Group Input 1 204 Set Up Group Input 2 207 Set Up Group Options 211 Set Up Group Output 203 Set Up Group Setpoint Ramp Rate 198 Set Up Group Tuning 196 Shed Time 74 Single Display Functionality 97 Single Display Parameters 98 Soak Segments 119 Software Options Status 191 March 2012 UDC2500 Universal Digital Controller Product Manual 227 Software Type 192 Software Upgrade Part Number 176 Software Upgrades 175 Software Version 192 Software Version Number 160 Solid State Relay Output 25 SP Ramp Set Up Group 39 SP Tuning 43 Specifications 8 Spprog 41 Sprate 40 Start Segment Number 119 Start Up Procedure For Operation 99 Station Address 73 Status Data 129 Status Tests 161 Stray Rejection 8 Suppression Devices 18 Switch Between Two Sets Via Keyboard 112 Switching Between Setpoints 102 7 Temperature Units 82 Test Failures 161 Thermocouple Inputs Using A Thermocoupl
180. oller will stay in the local setpoint mode when contact opens SP2 3 TO LOCAL SETPOINT TWO Contact closure puts the controller into local setpoint 2 DIR 4 TO DIRECT ACTION Contact closure selects direct controller action 70 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code HOLD lef TO HOLD Contact closure suspends Setpoint Program or Setpoint Ramp When contact reopens the controller starts from the Hold point of the Ramp Program unless the Ramp Program was not previously started via the RUN HOLD key This selection applies to either loop PID2 6 TO PID2 Contact closure selects PID Set 2 RUN 7 RUN Contact closure starts a stopped SP Ramp or Program Upper left character blinks R Reopening the contact puts controller in HOLD mode This selection applies to either loop Begn 8 EXTERNAL SP PROGRAM RESET Contact closure resets SP Program back to the beginning of the first segment in the program and places the program in the HOLD mode Program cycle number is not affected Reopening switch has no effect This selection applies to either loop ATTENTION Once the last segment of the setpoint program has timed out the controller enters the mode of action specified in the configuration data and the program cannot be reset to the beginn
181. om computer with Setpoint Ratio and Bias applied by the controller Within the Setpoint Range Limits in Engineering Units or Percent Shed The computer setpoint override will continue until SHED from communications occurs or the controller is placed into monitor mode through communications Doing periodic SLAVE READS within the shed time will allow the override to continue until communication is stopped and shed time elapses Does not apply to IR communications ATTENTION 0 Shed code 79 allows the override to continue indefinitely or until the reset shed timer register address 1B90 is written using function code 6 or register address 7F using function code 21 Any data value can be written because it is ignored When SP is overridden the upper display becomes COM momentarily and the lower display shows the CSP value as CSXXXX Table 10 7 1 Shed Timer Reset Parameter Register Data Range or Description Address Enumerated Selection Shed Timer Reset March 2012 UDC2500 Universal Digital Controller Product Manual 197 Modbus Read Write and Override Parameters plus Exception Codes Associated Parameters Refer to Table 10 8 for the codes to display or change any of the parameters associated with the computer setpoint Table 10 8 Computer Setpoint Associated Parameters Parameter Register Address O me O ear 0007 0008 007 008 Local Setpoint 1 0027 Computer Setpoint Ratio
182. on 17 TXD 2 RXD Position 18 TXD 1 RXD Table 2 8 shows how to connect a UDC directly to a PC utilizing a straight through cable wiring the UDC cable this way makes the necessary cross over connections Table 2 8 Terminals for connecting a UDC directly to a PC utilizing a straight through cable UDC Terminal UDC Signal Name RJ45 Socket Pin PC Signal Name Position 14 Shield Shield Shield Position 15 RXD 2 TXD Position 16 RXD 1 TXD Position 17 TXD 6 RXD Position 18 TXD 3 RXD Auxiliary Output Digital Inputs Auxiliary Digital Load 0 1000 Q Input 1 Digital Input 2 Connect shield to ground at one end only T Connect shield to ground at one end only Auxiliary Output and Digital Input 2 are mutually exclusive Figure 2 17 Auxiliary Output and Digital Inputs Option Connections March 2012 UDC2500 Universal Digital Controller Product Manual 31 Installation 2 Wire Transmitter Configure A2S1TY NONE A2S2TY NONE OUTPUT 3 INPUT 1 If necessary install a zener diode here to reduce voltage at the transmitter A 1N4733 will reduce the voltage at the transmitter to approximately 25 Vdc Figure 2 18 Transmitter Power for 4 20 mA 2 wire Transmitter Using Open 32 Collector Alarm 2 Output 2 Wire Transmitter Configure AUXOUT OUT Auxiliary Output Calibration ZEROVAL 4095 SPANVAL 4095 A
183. onformity with 72 23 EEC the Low Voltage Directive requires the user to provide adequate protection against a shock hazard The user shall install this controller in an enclosure that limits OPERATOR access to the rear terminals Mains Power Supply This equipment is suitable for connection to 90 to 250 Vac or to 24 Vac dc 50 60 Hz power supply mains It is the user s responsibility to provide a switch and non time delay North America quick acting high breaking capacity Type F Europe 1 2A 250V fuse s or circuit breaker for 90 250 Vac applications or 1 A 125 V fuse or circuit breaker for 24 Vac dc applications 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 Applying 90 250 Vac to an instrument rated for 24 Vac dc will severely damage the instrument and is a fire and smoke hazard When applying power to multiple instruments make certain that sufficient current is supplied Otherwise the instruments may not start up normally due to the voltage drop caused by the in rush current Controller Grounding PROTECTIVE BONDING grounding of this controller and the enclosure in which it is installed shall be in accordance with National and Local electrical codes To minimize electrical noise and transients that may adversely affect the system
184. ool Ethernet and Email Configuration Screens Introduction These screens only appear in instruments that have Ethernet Communications Ethernet and Email parameters can only be configured via the Process Instrument Explorer P LE Tool The figures in this section show screen shots of the Configuration Screens from the PC version of the P LE Tool Pocket PC Configuration Screens are generally similar in format but smaller Ethernet Configuration Screen This controller is shipped from the factory with the IP Address set to 10 0 0 2 the Subnet Mask set to 255 255 255 0 and the Default Gateway set to 0 0 0 0 Consult your Information Technologies IT representative as to how these should be configured for your installation The MAC address is printed on the product label located on the instrument s case These settings can be changed via the Ethernet Configuration Screen as shown in Figure 3 1 See Section 4 23 Configuring your Ethernet Connection for more information Process Instrument Explorer petations Services Help Online Configuration gt Screen helps to setup single parameter Write button helps to write the modified values into the Device Current Value New Value IP Address 164 145 185 214 164 145 185 Subnet Mask 25 255 3 ER Default Gateway Email Setup Time Events Communication Type Ethernet Transmission Status Figure 3 1 Ethernet Configu
185. oooonccnnncnnoncnocononcconoconaconncnnncnnncnn nono n con ncon anno nacnna ns 159 TROUBLESHOOTING SERVICE ccocoomiioiacincnonincianinanonindn ancianidad 161 OVVIE W e ee EEA de E a An e aa adhe einer eee 161 Troubleshooting Aids ia 162 PowerUp Desi it ir densvaiees E ETETE E E A 164 Stats Tests a eieren e a E a ete cheated ide 164 Back eround A RIO 165 Controll r Failure Symptoms ner s iccetsatecestetsccesstelesees thivseetosetanvenlasagesutleioee pasota bars dai 167 Lroubleshootins Procedures cuisine ias 168 Restoring Factory Configuration isese onien a e n e a aiee erea ea 177 Software Uperades aneen ani ii E EE Ha eae e E TE R eE 178 PARTS EIST a e a eA dci 180 Exploded Vi Wisin A lis 180 Removing the Chassis sisi cciisiv ssgateteast stot E bash stas E dota italia 182 MODBUS RTU FUNCTION CODES 0 ccccccsscceseeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeees 183 QV ELVIC Wer seiss si cette IA Gee aa esa ates ear RA a eee 183 General Informations rt A ceniudelan estes a 183 Function Code 20 14h Read Configuration Reference Data oonnoonnnnccnnncccnonccnnnnccnnnnccnncccnnnnos 185 9 3 1 Read Configuration Examples oooooonnnnnnnnocinonocononnnononannnnnonononononoconnnocnnn conan aran na cnnn cc nnc cios 187 Function Code 21 15h Write Configuration Reference Data onooonnnncnnnnccinncccnnocncnnnncnnnccnnnnnss 189 9 4 1 Write Configuration Examples ooooonnnccnoconococonoconcconnconnnononnno nono nonn nono nc nn nono
186. oosa 0 198 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes 10 7 Configuration Parameters Overview Listed on the next pages are the identifying codes for the parameters in the various Set up Groups in this instrument Most of the parameters are configurable through the hosts Some are Read Only and are indicated as such and cannot be changed Reading or Writing Do a Read or Write depending on your requirements using the identifying code and format code listed in the tables The range or selection available for each range is listed in the tables 10 7 1 Tuning Table 10 9 lists all the register addresses and ranges or selections for the function parameters in the Set up Group Tuning Table 10 9 Set up Group Tuning Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Gain 1 or PB 0001 001 FP R W 0 01 to 1000 Gain Note 1 0 1 to 1000 PB Rate 1 0002 002 FP R W 0 00 to 10 00 Note 1 Reset 1 0003 003 FP R W 0 02 to 50 00 Note 1 000D 013 FP R W 100 to 100 Gain 2 or PB 2 0004 004 FP R W 0 01 to 1000 Gain Note 1 0 1 to 1000 PB Rate 2 0005 005 FP se RIW__0 00 to 10 00 Note 1 Reset 2 0006 006 FP RIW__s0 02 to 50 00 Note 1 Cycle Time 1 15 21 INT R W 1 to 120 seconds Cycle Time 2 16 22 INT R W 1 to 120 seconds
187. or to the Input 2 terminals as shown in Figure 5 8 2 Place current source at zero before switching on 3 Do not switch current source ON OFF while connected to the instrument Current Source 6 no connection 7 2 2 Copper Leads Equal Length Figure 5 8 Wiring Connections for 0 to 20 mA or 4 to 20 mA Input Input 2 March 2012 UDC2500 Universal Digital Controller Product Manual 147 Input Calibration 0 to 2 Volts 0 to 5 Volts or 1 to 5 Volt Inputs Input 2 Refer to Figure 5 9 and wire the controller according to the procedure given in Table 5 12 Table 5 12 Set Up Wiring Procedure for 0 to 2 Volts 0 to 5 Volts or 1 to 5 Volts Input 2 1 Connect the copper leads from the calibrator to the Input 2 terminals as shown in Figure 5 8 2 Place voltage source at zero before switching on 3 Do not switch voltage source ON OFF while connected to the instrument on N Voltage wy y J Source 4 ARL KON S ZAA Copper Leads Equal Length Figure 5 9 Wiring Connections for 0 to 2 Volts 0 to 5 Volts or 1 to 5 Volts Input Input 2 5 7 Input 2 Calibration Procedure Preliminary Steps e Apply power and allow the controller to warm up for 30 minutes before you calibrate e Please read Subsection 5 6 before beginning the procedure e Make sure you have LOCK set to NONE See Subsection 3 4 Tuning Set Up Group Continued next page 148 UDC2500 Universal Digital Controller Product
188. or9 If the load current is less than the minimum rated value of 20 mA then there may be residual voltage across both ends of the load even if the relay is turned off Use a dummy resistor as shown to counteract this The total current through the resistor and the the load must exceed 20 mA Solid State Relays are zero crossing type Solid State relays are rated at 1 Amp at 25 C and derated linearly to 0 5 Amp at 55 C Customer should size fuse accordingly Use Fast Blo fuses only Electromechanical relays are rated at 5 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Dummy Resistor See Table 2 6 for relay terminal connections for other Output Algorithm Types 26 Figure 2 9 Solid State Relay Output UDC2500 Universal Digital Controller Product Manual March 2012 Installation Time Simplex Customer Supplied Electromechanical relay Output 1 Wa O o e tT N C Alarm Customer Supplied Load _ Relay Load Relay 2 Solid State relay Supply N O Power o eg eo Load A N C Alarm oa o Relay Load Relay 1 a vo 26 Power o 4 a ae is Time Duplex Customer Supplied Electromechanical relay Te _ IE e Customer Supplied Electromechanical relay ae FE Customer Supplied Solid State relay Load o Relay Load Supply To terminal Power D E i 7or9 O CAUTION Open collector outp
189. p Procedure Sep Operation ess ea 1 Select Control C setup Until you see Set up Group NA Upper Display SET Lower Display CONTRL 2 Select PID SETS Function Until you see NA Upper Display available selections Lower Display PID SETS 3 Select PID SETS AX or To select the type of function Available selections are Function ONE 1 set of constants 2 KBD 2 sets keyboard selectable 2 PR 2 sets auto switch at PV value 2 SP 2 sets auto switch at SP value 4 Set Tuning Function Refer to TUNING Set up group subsection 3 4 and set the Values for Each NA following tuning parameters Set PB or GAIN RATE T MIN or RPM CYCT1 or CTIX3 PB2 or GAIN2 RATE 2T 12MIN or I2RPM CYC2T2 or CT2X3 PIDSET1 will be used when PV or SP whichever is selected is greater than the switchover value PIDSET2 will be used when PV or SP whichever is selected is less than the switchover value 5 Set Switchover Function Until you see Value for2PRor Naa Upper Display the switchover value 2SP Selection Lower Display SW VAL A ory To select the switchover value in the upper display 112 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Switch between two sets via keyboard without automatic switch over Table 4 19 Procedure for Switching PID SETS from the Keyboard step operation press Result 1 Select Control Function
190. provides manual refresh if communication link is selected as Infrared Alarm Type Event Value Actual Alarm On Alarm Off Alarm1 SP1 IN1 HIGH END 500 00 249 99 Alarm1 SP2 NONE LOW BEGIN 0 00 0 00 Alarm2 SP1 NONE LOW BEGIN 0 00 0 00 Alarm2 SP2 NONE LOW BEGIN 0 00 0 00 Figure 4 7 Alarm Details Maintenance Screen 128 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Loop Data Digital Input Details This screen appears when you click on the Digital Inputs button on the Loop Data Maintenance Screen and shows the status of each Digital Input NONE in the Type column indicates that the Digital Input is disabled Highlighted Digital Inputs are currently active An asterisk indicates that the alarm has changed state since the last communications transaction This instrument has a maximum of two Digital Inputs Digital Inputs 3 through 8 will always appear as NONE Maintenance Data Digital Input Details t Screen shows Digital Input details Here Active Digital Inputs are highlighted Also Indicates status has changed since last View NONE DIS Open NONE DIS Open NONE DIS Open NONE DIS Open NONE DIS Open NONE DIS Open NONE DIS Open Close Figure 4 8 Digital Input Details Screen March 2012 UDC2500 Universal Digital Controller Product Manual 129 Monitoring and Operating the Controller Status Data Select Status Data from the Mai
191. pt 0 10 Volts 24 mV or Volt source Use Thermocouple extension wire only Supply O The 250 ohm resistor for milliamp inputs or the voltage divider for 0 10 Volt inputs are supplied with the controller when those inputs are specified These items must be installed prior to start up when the controller is wired For 0 20 mA applications the resistor should be located at the transmitter terminals if Burnout detection is desired Splice and tape this junction between the two thermocouples This junction may be located anywhere between the thermocouples and the instrument terminals it does not need to be close to the other thermocouple junctions Both thermocouples must be of the same type For best accuracy the two thermocouples should be matched or preferably made from the same batch of wire This controller does not produce a steady current for burnout detection For that reason when a thermocouple is used in parallel with another instrument it may be desirable to configure the burnout selection for this controller to NOFS and use the burnout current from the other instrument to also drive this controller The millivolt values for the Thermocouple Differential Input are for a pair of J thermocouples at an ambient temperature mean of 450 F 232 C Figure 2 6 Input 1 Connections UDC2500 Universal Digital Controller Product Manual March 2012 Installation Input 2 Volts Input Milliamps Input sourc
192. put will appear Likewise if the controller does not have a relay output then none of the prompts that need a relay output will appear ATTENTION For all Duplex Output forms PID heat parameters apply for controller output greater than 50 PID cool parameters apply for controller output less than 50 RLY 0 TIME SIMPLEX This output algorithm uses Digital Output 1 for Time Proportional Control The output is updated per the Loop sampling rate selection Time Proportional Output has a resolution of 4 44 msec Cycle Time is adjustable from 1 to 120 seconds RLY2 TIME SIMPLEX This output algorithm uses Digital Output 2 for Time Proportional Control The output is updated per the Loop sampling rate selection Time Proportional Output has a resolution of 4 44 msec Cycle Time is adjustable from 1 to 120 seconds 52 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code CURRENT SIMPLEX Type of output using one 4 mA to 20 mA signal that can be fed into a positive or negative grounded load of 0 to 1000 ohms This signal can easily be configured for 4 20 mA or 0 20 mA operation via the CRANGE configuration below TIME DUPLEX T his output algorithm uses Digital Outputs 1 and 2 for Duplex Time Proportional Control The outputs are updated per the Loop sampling rate sele
193. r Data Data Range or Description Address Type Enumerated Selection Input 1 7B 123 FP In Engineering Units or Percentage Input 2 7C 124 FP In Engineering Units or Percentage PV SP Output 7A 122 FP In Engineering Units or Percentage 10 3 Read Software Options Status Read Doing a Read of register address 00B9 listed in Table 10 2 will tell you which of the available options are enabled installed or disabled not installed Table 10 2 Option Status Parameter Register Data Data Range or Description Address Type Enumerated Selection Option Status 00B9 185 INT See Figure 10 1 Read only The data field in the response message will be a decimal number from 0 to 255 Convert the decimal number to binary as shown in Figure 10 1 to determine which options are or are not active EE 0 to 255 Convert decimal to binar Ez Dual Display SP Programming 0 not installed 1 installed Limit Controller EXAMPLE 3 Binary 0 o o o o o 1 1 srProgamming insta Dual Display installed Figure 10 1 Software Option Status Information 194 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes 10 4 Miscellaneous Read Onlys 10 4 1 Register Addresses for Read Onlys The identifying register addresses listed in Table 10 3 represent some information that is Read only No Writes allowed Table 10 3 Miscellaneous Read Onlys
194. r the prompts for SP Programming may be found in Section 4 21 Setpoint Programming The listing below is only for reference purposes Start Segment Number End Segment Number Engineering Units for Ramp Segments TIME in hours minutes RATE in Enineering units per minute RATE in Enineering units per hour Number of Program Recycles Guaranteed Soak Deviation Value Program Termination State UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeri Numeric c Code Code STATE DIS 0 Program State at Program End HOLD ToBEGN DIS Reset Rerun SP Program KEY Keyboard PVSTRT DIS DISABLE LSP1 is used as the initial ramp ENAB setpoint ENABLE Current PV value is used as the initial ramp setpoint SG1 RP 0 99hours 0 Segment 1 Ramp Time or SG3 RP 59minutes Segment 1 Ramp Rate eae aaa SG5 RP ngineering Select TIME EU M or EU H at prompt SG7 RP Units minute or SG9 RP Engineering Units RPUNIT All ramps will use the same selection SG11 RP hour Enter a Value Soak Segments Setpoint Value within the Setpoint Limits 0 99 Hours 0 59 Soak Segments Duration Minutes March 2012 UDC2500 Universal Digital Controller Product Manual 43 Configuration 3 6 Accutune Set Up Group Introduction 44 Accutune ITI automatically calculates GAIN RATE and RESET TIME PID tuni
195. ram can be placed in RUN or HOLD state through a remote dry contact connected to optional digital input terminals as follows RUN contact closure places Program in RUN state OR HOLD contact closure places Program in HOLD state Opening the contact will cause the Controller to revert to its original state UDC2500 Universal Digital Controller Product Manual 125 Monitoring and Operating the Controller 4 22 P I E Tool Maintenance Screens Introduction This controller uses special P I E Tool Maintenance Screens which allow remote access and access to functions not accessible via the controller s display and keyboard The figures in this section show screen shots of the Maintenance Screens from the PC version of the P LE Tool Pocket PC Maintenance Screens are generally similar in format but smaller ATTENTION Your instrument may not have all of the screens and parameters shown in this section Loop Data Select Loop Data from the Maintenance Data menu Maintenance Data Status Data Ethernet Status Figure 4 5 Maintenance Data Menu 126 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Maintenance Loop Data tj Screen refreshes automatically if the communication link is selected as AS485 or Ethernet Tool provides manual refresh if communication link is selected as Infrared Select Loop Data LOOP1 bi Pv 350 02 OPE OK SP 350 00 a OK 34 02
196. rameters Press the LOWER DISPLAY key to scroll through the operating parameters listed in Table 4 3 The lower display will show only those parameters and their values that apply to your specific model Table 4 3 Lower Display Key Parameter Prompts OT XX X OUTPUT Output value is percent for Three Position Step control this is an estimated motor position and shown with no decimal place SP XXXX LOCAL SETPOINT 1 Also current setpoint when using SP Ramp 2LXXXX LOCAL SETPOINT 2 RSXXXX REMOTE SETPOINT 2NXXXX INPUT 2 DEXXXX DEVIATION Maximum negative display is 999 9 PIDS X TUNING PARAMETER SELECTED SET where X is either 1 or 2 HH MM TIME REMAINING Time that remains on timer in Hours Minutes ew 0 00 ELAPSED TIME Time that has elapsed on timer in Hours Minutes RPXXXM SETPOINT RAMP TIME Time remaining in the setpoint ramp in minutes AX XXX AUXILIARY OUTPUT SnXXXX SP RATE SETPOINT Current setpoint for setpoint rate applications BIXXXX BIAS Displays the manual reset value for algorithm PD MR To BGn TO BEGIN Resets Setpoint Program back to beginning of the program NoTUNE Unit is currently not in Accutune process DoSLOW Accutune Slow tuning process is operating DoFAST Accutune Fast tuning process is operating POSXX XX Three position March 2012 UDC2500 Universal Digital Controller Product Manual 95 Monitoring and Operating the Controller 4 5 3 Diagnostic Messages The UDC2500 performs background test
197. ration 2 Check the field wiring Output impedance must be less than or equal to 1000 ohms 3 Check the output Change the AUX OUT selection to 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 4 Recalibrate the Auxiliary output Refer to Section 6 Output Calibration for details 5 Change Auxiliary Output board Installation instructions provided with new board 6 Change Controller 176 UDC2500 Universal Digital Controller Product Manual March 2012 Troubleshooting Service 7 8 Restoring Factory Configuration Introduction This procedure restores the configuration of the instrument back to the Factory Settings per Section 3 17 ATTENTION Restoring the factory configuration overwrites all user entered configuration changes This procedure cannot be undone it is a one way process Table 7 15 explains how to restore Factory Configuration Table 7 15 Restoring Factory Configuration Step What to do 1 Turn off the power to the instrument for at least five seconds 2 Turn the power back on and simultaneously press the FUNCTION and Ax keys This must be done while TEST DONE is being displayed 3 If step 2 was performed correctly the instrument will now display UDC Upper UPDATE Lower 4 Press the FUNCTION Key The instrument will now display DIS Upper RE
198. ration Screen March 2012 UDC2500 Universal Digital Controller Product Manual 85 Configuration WARNING After you change the IP Address you will no longer be able to communicate with the instrument via Ethernet until you change the P I E Tool s IP Address setting in the PC COMM SETUP section to match the setting that is now in your controller See Section 4 23 Configuring your Ethernet Connection for more information Email Configuration Screen 86 This controller may be configured to support sending an Email when an alarm occurs Emails are sent only when the selected alarm transitions from the OFF to the ON state Estad Y nen dow yourep com sas s 167 UOC EON Corista tex ener 4 Alam 4 Set Pore t Fire Pgh PV aiun Setzcrd Y hs baen actovibad Serd Martonart e Pesar to chath Flow Valve 816 Figure 3 2 Email Configuration Screen This controller cannot receive Emails so it is suggested that you configure the From Email window with a non Email style address that will make it easy for you to determine which controller sent the Email For Email technical reasons the entry in the From Email window cannot have spaces See Figure 3 2 If you do not know your SMTP IP Address for outgoing Email then contact your Information Technologies IT representative If your PC is on the same LAN that will be used by the controller and which also connects to the Email server then the SMTP IP Address may gener
199. rch 2012 UDC2500 Universal Digital Controller Product Manual 47 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code DUPLEX ON OFF is an extension of this algorithm when the output is configured for Duplex It allows the operation of a second ON OFF output There is a deadband between the operating ranges of the two inputs and an adjustable overlap hysteresis of the on and off states of each output Both Deadband and Hysteresis are separately adjustable With no relay action the controller will read 50 ATTENTION Other prompts affected OUTHYS and DEADBD PID A is normally used for three mode control This means that the output can be adjusted somewhere between 100 and 0 lt applies all three control actions Proportional P Integral 1 and Derivative D 1o the error signal Proportional Gain Regulates the controllers output in proportion to the error signal the difference between Process Variable and Setpoint Integral Reset Regulates the controller s output to the size of the error and the time the error has existed The amount of corrective action depends on the value of proportional Gain Derivative Rate Regulates the controller s output in proportion to the rate of change of the error The amount of corrective action depends on the value of proportional Gain PID B Unlike the PID
200. re 4 14 CommunicationT ype Ethernet Select Type to setup Figure 4 14 Ethernet Communications Type Selection UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller Now set your Ethernet address to 10 0 0 2 as shown in Figure 4 15 Communication Setup Ethernet ts Screen helps to setup Ethemet parameters Ethermet Parameters IP Address Timeout 1 20 sec Retries Figure 4 15 Ethernet Communications Address Close the Ethernet configuration window and then single click on the Online Configuration button c ll noe Online Configuration Then click on the Start button The P I E Tool should start uploading the configuration information from the controller as shown in Figure 4 16 March 2012 UDC2500 Universal Digital Controller Product Manual 135 Monitoring and Operating the Controller Online Configuration cS To terminate Upload click on Abort button Device Type UDC3500 vi Upload Status E Please wait Upload is in Progress wa Figure 4 16 Configuration Upload in Progress Once the upload is complete click on the Ethernet amp Email Group Configure your Ethernet and Email parameters per Section 3 16 Once you have changed the Ethernet settings and downloaded them to your controller you will no longer be able to communicate with it until you change the IP address in the P L
201. required These levels are e NONE No Lockout All groups Read Write e CAL Calibration prompts are deleted from the Setup List e CONF Timer Tuning SP Ramp and Accutune are Read Write All other Setup groups are Read only Calibration Group is not available e VIEW Timer Tuning and SP Ramp are Read Write No other parameters are available e ALL Timer Tuning and SP Ramp are Read only No other parameters are viewable See Subsection 3 4 Tuning Parameters Set Up Group prompts to select one of the above Security Code see Subsection 4 3 92 UDC2500 Universal Digital Controller Product Manual March 2012 Individual key lockout Monitoring and Operating the Controller There are three keys that can be disabled to prevent unauthorized changes to the parameters associated with these keys First set the Lock prompt to NONE These keys are AT E a REA Key M K Key you can disable the Run Hold key for Set Point Programming at configuration Set Up group prompt Tuning function prompt RN HLD you can disable the Auto Manual key at configuration Set Up group prompt Tuning function prompt AUTOMA you can disable the Set Point Select function key at configuration Set Up group prompt Tuning function prompt SP SEL See Subsection 3 4 Tuning Parameters Set Up Group prompts to enable or disable these keys Key error When a key is pressed and the prompt
202. roduct Manual 79 Configuration Function Prompt Selection or Range of Setting Lower Display Upper Display ee EV A1S2TY A1S2VA A1S2HL A1S2EV A2S1TY A2S1VA 80 ea Code 1106 1106 1107 Value in engineering units Value in engineering units Numeric Code Parameter Definition If Setpoint Programming is enabled and if the Alarm Type is configured for Event On Off ALARM 1 SEGMENT EVENT 1 Select whether you want the alarm type chosen in prompt A1S1TYPE to alarm the beginning or end of a segment in setpoint Ramp Soak programming BEGINNING OF SEGMENT END OF SEGMENT ATTENTION Alarms configured for events will not operate on Setpoint Program segments of zero length ALARM 1 SETPOINT 2 TYPE Select what you want Setpoint 2 of Alarm 1 to represent The selections are the same as A1S1TYPE ALARM 1 SETPOINT 2 VALUE This is the value at which you want the alarm type chosen in prompt A1S2TYPE to actuate The details are the same as A1S1 VAL ALARM 1 SETPOINT 2 STATE Same as A1S1HL ALARM 1 SEGMENT EVENT 2 Same as A1S1EV ALARM 2 SETPOINT 1 TYPE Select what you want Setpoint 1 of Alarm 2 to represent The selections are the same as A1S1TYPE ATTENTION Not applicable with Relay Duplex unless using Dual Relay PWA ALARM 2 SETPOINT 1 VALUE T his is the value at which you want the alarm type chosen in prompt A2S1TYPE to actuate The details are the same
203. rol Connections with Dual Relay Option March 2012 UDC2500 Universal Digital Controller Product Manual 29 Installation 30 COMMUNICATION MASTER D B SHLD D A 17 D B Q KN S IEA 120 OHMS Connect shield TO OTHER to ground at one COMMUNICATION CONTROLLERS end only 120 OHMS ON LAST LEG Do not run the communications lines in the same conduit as AC power Use shielded twisted pair cables Belden 9271 Twinax or equivalent Figure 2 15 RS 422 485 Communications Option Connections COMMUNIGTION MASTER G OR SWITCH SHLD TXD TXD RXD RXD OO Do not run the communications lines in the same conduit as AC power Correct connections may require the use of an Ethernet cross over cable Q Use Shielded twistedpair Category 5 STP CAT5 Ethernet cable G Use Switch rather than Hub to maximize performance Figure 2 16 Ethernet Communications Option Connections Figure 2 16 and Table 2 7 shows how to connect a UDC to a MDI Compliant Hub or Switch utilizing a straight through cable or for connecting a UDC to a PC utilizing a crossover cable UDC2500 Universal Digital Controller Product Manual March 2012 Installation Table 2 7 Terminals for connecting a UDC to a MDI Compliant Hub or Switch UDC Terminal UDC Signal Name RJ45 Socket Pin Switch Signal Name Position 14 Shield Shield Shield Position 15 RXD 6 TXD Position 16 RXD 3 TXD Positi
204. s 125 Parts Identification 178 Parts List 177 PD With Manual Reset 48 Permissible Wiring Bundling 18 Physical Considerations 15 PID A 47 PID B 47 Position Proportional Or 3 Position Step Test Failures 161 Power Consumption 10 Power Failure Symptoms 166 Power Inrush Current 10 Power Line Frequency 83 Power Outage 124 Power Outage 117 Power Up Tests 161 Pre Installation Information 8 Process Instrument Explorer 4 Program Contents 118 Program Record Sheet 122 Program State 120 Program Termination State 120 Proportional Band 35 Proportional Band 2 36 Proportional Band Units 66 Pv Hot Start 115 R Ramp Time Or Rate Segments 118 Ramp Unit 119 Ramp Soak Profile Example 120 Rate 35 Rate 2 36 Ratio 57 60 Read Onlys 192 Reading Control Data 190 Recycle Number 119 Register Address Structure 181 Register Count 181 Relay Cycle Times 54 Remote Setpoint Source 63 Removing The Chassis 179 Reset 36 Reset 2 36 Reset Program To Beginning 120 Reset Units 66 Restore Factory Calibration 149 Restore Output Factory Calibration 156 Restoring Factory Configuration 174 Reverse Acting Control 64 RTD Inputs 141 Run Hold Key 92 Run Hold Key 116 Run Hold Key Lockout 38 Run Monitor The Program 123 S Security Code 37 Security Code 90 Set Point Select Function Key 92 Set Up Group 33 Set Up Wiring Procedure For Auxiliary Output 154 Setp
205. s Table 3 13 OPTION Group Numeric Code 900 Function Prompts Function Prompt Selection or Range of Setting Lower Display Upper Display Numeric Numeric Code Code AUXOUT 901 AUXILIARY OUTPUT SELECTION Parameter Definition This selection provides an mA output representing one of several control parameters The display for auxiliary output viewing will be in engineering units for all but output Output will be displayed in percent ATTENTION Other prompts affected by these selections 4mA VAL and 20mA VAL ATTENTION Output cannot be configured when Three Position Step Control is used DIS 0 NO AUXILIARY OUTPUT IN1 1 INPUT 1 This represents the configured range of input 1 FOR EXAMPLE Type J Thermocouple 0 F to 1600 F O F display 0 output 1600 F display 100 output IN2 2 INPUT 2 represents the value of the configured range of input 2 PROC 3 PROCESS VARIABLE Represents the value of the Process Variable PV Input XxRatioX BiasX 68 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code DEVIATION PROCESS VARIABLE MINUS SETPOINT Represents 100 to 100 of the selected PV span in engineering units Zero deviation will produce a center scale 12 mA or 50 output A negative deviation equal in magnitude to the Auxiliary
206. s an adjustable gap between the operating ranges of output 1 and output 2 in which neither output operates positive value or both outputs operate negative value Time Duplex On Off Duplex Three Position Step HYSTERESIS OUTPUT RELAY is an adjustable overlap of the ON OFF states of each control output This is the difference between the value of the process variable at which the control outputs energize and the value at which they de energize ATTENTION control Only applicable for ON OFF FAILSAFE OUTPUT VALUE The value used here will also be the output level when you have Communications SHED set to failsafe or when NO BURNOUT is configured and Input 1 fails ATTENTION Applies for all output types except Three Position Step Control THREE POSITION STEP FAILSAFE OUTPUT 0 PCT Motor goes to closed position 100 PCT Motor goes to open position March 2012 Function Prompt Selection or Range of Setting Lower Display Upper Display Numeric Numeric Code Code 0 1 FSMODE 817 PBorGN 818 NOTE 1 Does not apply to Three Position Step Control Configuration Parameter Definition FAILSAFE MODE NON LATCHING Controller stays in last mode that was being used automatic or manual output goes to failsafe value NOTE 1 NOTE 2 LATCHING Controller goes to manual mode output goes to failsafe value NOTE 2 PROPORTIONAL BAND UNITS Select one of the following for th
207. s of establishing the appropriate values for the tuning constants you are using so that your controller responds correctly to changes in process variable and setpoint You can start with predetermined values but you will have to watch the system to see how to modify them The Accutune feature automatically selects Gain Rate and Reset on demand ATTENTION Because this group contains functions that have to do with security and lockout we recommend that you configure this group last after all other configuration data has been loaded Function Prompts Table 3 4 TUNING Group Numeric Code 100 Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code RATE action in minutes affects the controller s output whenever the deviation is changing and affects it more when the deviation is changing faster 0 00 to 10 00 minutes 0 08 or less OFF E PROPORTIONAL BAND simplex is the PB or GAIN PB 0 1 to 1000 percent of the range of the measured Gain 0 01 to variable for which a proportional controller 1000 will produce a 100 change in its output GAIN is the ratio of output change over the measured variable change that caused it 100 G PB where PB is the proportional band in If the PB is 20 then the Gain is 5 And at those settings a 3 change in the error signal SP PV will result in a 15 change in the controller s output due
208. s to verify data and memory integrity If there is a malfunction a diagnostic message will be shown on the lower display In the case of more than one simultaneous malfunction only the highest priority diagnostic message will be displayed Table 4 4 shows the error messages in order by priority If any of these diagnostic messages appear on the lower display refer to Section 7 Troubleshooting for information on how to correct the problem Table 4 4 Diagnostic Messages Prompt Deseripton EE FAIL Unable to write to non volatile memory IN1FL Two consecutive failures of input 1 integration IN2FL Two consecutive failures of input 2 integration CFGERR Configuration Errors Low limit greater than high limit for PV SP Reset or Output IN1RNG Input 1 Out of Range Out of range criteria Linear range 10 out of range Characterized range 1 out of range IN2RNG Input 2 Out of Range Same as Input 1 PV LIM PV Out of Range PV PV source x PV source ratio PV source bias FAILSF Failsafe conditions for failsafe are EEROM Test Failed Scratch Pad RAM Test Failed Configuration Test Failed Field or Factory Cal Test Failed Check the Status group RV LIM Remote Variable Out of Range RV RV source x RV source ratio RV source bias SEG ERR Segment Error SP Program starting segment number is less than ending segment number LOCK The lockout feature has been enabled to prevent unauthorized chan
209. sabled 1 Enabled Single SP Ramp 19 25 FP R W 0 to 255 minutes Time Final Ramp SP 001A 026 FP R W PV Range in Engineering Value Units SP Rate 240 0 Disabled 1 Enabled Rate Up EU HR 006C ab R W 0 to 9999 Rate Down 006D 109 0 to 9999 EU HR Setpoint 00B2 178 0 Disabled Program 1 Enabled Sense fa CO fe CI End Segment 00B0 0 Soak 2 Soak 1 Soak 4 2 Soak 6 3 Soak 8 4 Soak 10 5 Soak 12 Engineering Units 00B6 182 INT RW 0 HRS MIN or Ramp 1 Degrees Minute Segments 2 EU Hour Program Recycles 59 89 FP R W O to 100 Guaranteed Soak 0057 087 FP R W 0 to 99 9 0 no soak Deviation Program End 00B5 181 INT R W 0 Disable SP Program State 1 Hold at Program End March 2012 UDC2500 Universal Digital Controller Product Manual 201 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Controller Status 00B4 180 INT R W 0 Last Setpoint and Mode at Program End 1 Manual Failsafe Output Reset SP Program 00B3 179 INT R W 0 Disable ToBEGIN 1 Via Keypad PV Hotstart 00E2 226 INT R W 0 Disabled 1 Enabled Segment 1 Ramp 0039 057 FP R W 99 59 0 99 Hrs 0 59 Min or 0 to 999 Degre
210. sal Digital Controller Product Manual 153 Output Calibration 6 2 Current Output Calibration Introduction Calibrate the controller so that the output provides the proper amount of current over the desired range The controller can provide an output current range of from 0 to 21 milliamperes and is usually calibrated at 4 mA for 0 of output and 20 mA for 100 of output or any other values between 0 mA and 21 mA It is not necessary to re calibrate the controller in order to change from 4 to 20 mA operation over to 0 to 20 mA operation a simple configuration change is all that is required See the CO RANGE configuration in Sub section 3 8 for details Equipment Needed You will need a standard shop type milliammeter with whatever accuracy is required capable of measuring 0 to 20 milliamps Calibrator Connections Refer to Figure 6 1 and wire the controller according to the procedure given in Table 6 1 Table 6 1 Set Up Wiring Procedure for Current Output 1 Apply power and allow the controller to warm up 30 minutes before you calibrate 2 Set LOCK in the Tuning Set Up group to NONE 3 Tag and disconnect the field wiring at the rear of the controller from terminals 21 2 and 19 See Figure 6 1 4 Connect a milliammeter across these terminals Milliammeter 4 9 SEA A SA 52 ANO O Figure 6 1 Wiring Connections for Calibrating Current Output 154 UDC2500 Universal Digital Controller Product Ma
211. scaled per the range of the selected variable and can be set anywhere between 0 to 21 mA The Second Current Output is mutually exclusive with the second Digital Input Resolution 12 bits over 0 to 21 mA Accuracy 0 05 of full scale Temperature Stability 0 01 F S C Load Resistance 0 to 1000 ohms Alarm Outputs Optional One SPDT Electromechanical relay A second alarm is available if the second control relay is not used for control purposes or when the Dual Relay Option is used Up to four setpoints are independently set as high or low alarm two for each relay Setpoint can be on any Input Process Variable Deviation Manual Mode Failsafe PV Rate RSP Mode Communication Shed or Output A single adjustable hysteresis of 0 0 to 100 0 is provided The alarm can also be set as an ON or OFF event at the beginning of a Setpoint ramp soak segment Alarm Relay Contacts Rating Resistive Load 5 amps at 120 Vac or 240 Vac or 30 Vdc Isolation Functional Analog Inputs are isolated from all other circuits at 850Vdc for 2 seconds but not from each other Analog Outputs are isolated from all other circuits at 850Vdc for 2 seconds AC Power is electrically isolated from all other inputs and outputs to withstand a HIPOT potential of 1900Vdc for 2 seconds per Annex K of EN61010 1 Relay Contacts with a working voltage of 115 230 Vac are isolated from each other and all other circuits at 345Vdc for 2 seconds M
212. scan the Set Up groups in both directions Stop at the Set Up group title that describes the group of parameters you want to configure Then proceed to the next step 3 Select a Function Function Upper Display the current value or selection for the first Parameter Ness function prompt of the selected Set Up group Lower Display the first Function prompt within that Set Up group Sequentially displays the other function prompts of the Set Up group you have selected Stop at the function prompt that you want to change then proceed to the next step 4 Change the Increments or decrements the value or selection that Value or orm appears for the selected function prompt If you change the Selection value or selection of a parameter while in Set Up mode then O decide not to enter it press M A RESET once the original value or selection is recalled 5 Enter the Value Function Enters value or selection made into memory after another or Selection N 4 key is pressed Exits configuration mode and returns controller to the same state it was in immediately preceding entry into the Set Up mode It stores any changes you have made If you do not press any keys for 30 seconds the controller times out and reverts to the mode and display used prior to entry into Set Up mode 6 Exit Configuration EN ES March 2012 UDC2500 Universal Digital Controller Product Manual 35 Configuration 3 4 Tuning Set Up Group Introduction Tuning consist
213. supplementary bonding of the controller enclosure to a local ground using a No 12 4 mm copper conductor is recommended Control Alarm Circuit Wiring The insulation of wires connected to the Control Alarm terminals shall be rated for the highest voltage involved Extra Low Voltage ELV wiring input current output and low voltage Control Alarm circuits shall be separated from HAZARDOUS LIVE gt 30 Vac 42 4 Vpeak or 60 Vdc wiring per Permissible Wiring Bundling Table 2 5 Electrical Noise Precautions Electrical noise is composed of unabated electrical signals which produce undesirable effects in measurements and control circuits 18 UDC2500 Universal Digital Controller Product Manual March 2012 Installation Digital equipment is especially sensitive to the effects of electrical noise Your controller has built in circuits to reduce the effect of electrical noise from various sources If there is a need to further reduce these effects e Separate External Wiring Separate connecting wires into bundles See Permissible Wiring Bundling Table 2 5 and route the individual bundles through separate conduit metal trays Use Suppression Devices For additional noise protection you may want to add suppression devices at the external source Appropriate suppression devices are commercially available ATTENTION For additional noise information refer to document number 51 52 05 01 How to Apply Digital Instrumentation in Severe El
214. t to the current PV value and the Rate or Ramp or Program then starts from this value 116 UDC2500 Universal Digital Controller Product Manual March 2012 Monitoring and Operating the Controller RUN HOLD key You can start or stop the Ramp or Program using the RUN HOLD key 4 19Setpoint Ramp Introduction When you have configured a SETPOINT RAMP the ramp will occur between the current local setpoint and a final local setpoint over a time interval of from 1 to 255 minutes You can RUN or HOLD the ramp at any time Configuration Check Make sure e SPRAMP is enabled e A Ramp Time TIMIN in minutes has been configured e A final setpoint value FINLSP has been configured See Subsection 3 5 Configuration group SPRAMP for details Operation Running a Setpoint Ramp includes starting holding viewing the ramp ending the ramp and disabling it See Table 4 24 Table 4 24 Running A Setpoint Ramp step Operation Press Tan 1 Select Automatic Mode A indicator is on Upper Display Hold and PV value Lower Display SP and Present value 2 Set Start Setpoint Until start SP value is in lower display Y Lower Y Upper Display Hold and PV value Lower Display SP and start SP value 3 Start the Ramp You will see Upper Display Run and a changing PV value Lower Display SP and a changing SP value increasing or decreasing toward a final SP value 9 E7 4 Hold Run the Y Run N This holds the ramp at th
215. ta Screen refreshes automatically if the communication link Ls is selected as Ethernet Tool provides manual refresh if communication link is selected as Infrared Ethemet Status NETWRKOK Device Type UDC3500 014 Y1 Figure 4 10 Ethernet Status Maintenance Screen March 2012 UDC2500 Universal Digital Controller Product Manual 131 Monitoring and Operating the Controller 4 23 Configuring your Ethernet Connection Introduction This controller is shipped from the factory with the address for Infrared IR communications set to 3 the Ethernet IP Address set to 10 0 0 2 the Ethernet Subnet Mask set to 255 255 255 0 and the Ethernet Default Gateway set to 0 0 0 0 Consult your Information Technologies IT representative as to how these should be configured for your installation The MAC address is printed on the product label located on the instrument s case Only the P I E Tool can be used to configure Ethernet parameters The figures in this section show screen shots from the PC version of the P LE Tool Screens Pocket PC Screens are generally similar in format but smaller The P I E Tool can connect to your controller via either Ethernet communications port or the Infrared IR communications port Configuring the Controller via Infrared Communications 132 If connecting via IR and assuming that the instrument s IR address has not been changed from its factory setting of 3 then configure your Communicat
216. tenance information on the controller instantly get information on the current operating parameters digital inputs and alarm status identify internal or analog input problems Question What if I have several controllers on the same panel How can I be sure I am communicating with the correct one Answer The infrared port of the controller is normally off You activate the infrared port by pressing any controller s key You can now communicate After 4 minutes the port will be shut down again Also in the Communications Group IR ENABLE may be disabled to prohibit IR communications Figure 1 3 Depiction of infrared communications 1 4 CE Conformity Europe This product is in conformity with the protection requirements of the following European Council Directives 73 23 EEC the Low Voltage Directive and 89 336 EEC the EMC Directive Conformity of this product with any other CE Mark Directive s shall not be assumed Product Classification Class I Permanently connected panel mounted Industrial Control Equipment with protective earthing grounding EN61010 1 Enclosure Rating This controller must be panel mounted with the rear terminals enclosed within the panel The front panel of the controller is rated at NEMA4X and IP66 when properly installed Installation Category Overvoltage Category Category II EN61010 1 March 2012 UDC2500 Universal Digital Controller Product Manual 5 Introduction Rat
217. ter address OOAD and enter the value for the setpoint chosen using register address in Table 10 5 Table 10 5 Setpoint Code Selections Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal Local Setpoint 1 0027 039 FP R W Value within the setpoint range limits Local Setpoint 2 0035 053 FP R W Value within the setpoint range limits Number of Local OOAD 173 INT R W 00 Local Setpoint 1 Setpoints only 01 2nd Local Setpoint via keyboard or communications Associated Parameters Refer to Table 10 6 to display or change any of the parameters associated with the setpoint Table 10 6 Setpoint Associated Parameters Parameter Register Address Computer Setpoint 007D 196 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes 10 6 Using a Computer Setpoint Overriding Controller Setpoint Overview You can use a setpoint generated from the computer to override the setpoint being used by the controller The value generated by the computer will have ratio and bias applied by the controller Register Addresses Use the identifying code in Table 10 7 to enter the computer setpoint Table 10 7 Computer Setpoint Selection Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal Computer Value fr
218. ter count definitions are 0001 Integer Data 0002 Floating Point Data 184 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus RTU Function Codes 9 3 Function Code 20 14h Read Configuration Reference Data Description Function code 20 14 Hex is used in this instrument to read information stored in its configuration database Each configuration item is explicitly addressed by a file number and register address IEEE 32 bit floating point and 16 bit integer formats are supported Request and Response Formats The Request and Response formats for Function code 20 14 Hex are shown below Details for each block reference follow Request Message Format Slave Function Byte Reference File Register Register es Address Code 14 Count Type Number Address Count Data Data Byte Count Byte Count The Byte Count equals the number of bytes transmitted in either the request or response message and will be the minimum number required to transmit all requested data Data Byte Count The Data Byte Count is the number of data bytes of the sub response including the Reference Type but not including itself A floating point sub response has four bytes of data and one byte representing the reference type making the data byte count equal to five March 2012 UDC2500 Universal Digital Controller Product Manual 185 Modbus RTU Function Codes Reference Type Definitions The Reference Type definition is always 06
219. tes A Set Point Rate SPRATE lets you configure a specific rate of change for any local setpoint change A single Set Point Program SP PROG with up to 12 segments can be configured For more information on Set Point Rate Ramp and Programming see Sections 4 18 through 4 21 You can start and stop the ramp program using the RUN HOLD key PV Hot Start is a configurable feature and means that at initialization the setpoint is set to the current PV value and the Ramp or Rate or Program then starts from this value Function Prompts Table 3 5 SPRAMP Group Numeric Code 200 Function Prompts Function Prompt Lower Display Selection or Range of Setting Upper Display Numeri Numeric c Code Code DIS ENAB SP RAMP SP Program must be disabled for SP Ramp prompts to appear 0 to 255 minutes 40 UDC2500 Universal Digital Controller Product Manual 0 1 Parameter Definition SINGLE SETPOINT RAMP Make a selection to enable or disable the setpoint ramp function Make sure you configure a ramp time and a final setpoint value SP Programming must be disabled DISABLE SETPOINT RAMP Disables the setpoint ramp option ENABLE SETPOINT RAMP Allows the single setpoint ramp prompts to be shown SETPOINT RAMP TIME Enter the number of minutes desired to reach the final setpoint A ramp time of 0 implies an immediate change of setpoint March 2012 Function Prompt Lower Display Numeri c C
220. the 100 range value for your particular input sensor See Table 5 1 for Voltage Degrees or Resistance equivalents for 100 range values e Wait 15 seconds and If Then you are calibrating a Thermocouple input go to step 4 you are calibrating other than a go to step 5 Thermocouple input 4 Check the Cold Function The calculations for zero and span are now stored and you Junction NA Will see Temperature Upper Display The cold junction temperature at the rear terminals Lower Display CJTEMP 10004 The value in the upper display is in tenths of a degree It is the current reading of the temperature as measured at the thermocouple terminals and recognized by the controller You can change this value if it is in error using the A orv keys WARNING The accuracy of the controller is directly affected by the accuracy of this value Itis recommended that this value not be changed under normal circumstances The controller stores the calibration constants and exits the calibration mode 5 Exit the Calibration Mode 146 UDC2500 Universal Digital Controller Product Manual March 2012 Input Calibration 5 6 Input 2 Set Up Wiring 0 to 20 mA or 4 to 20 mA Inputs Input 2 Refer to Figure 5 8 and wire the controller according to the procedure given in Table 5 13 Table 5 11 Set Up Wiring Procedure for 0 to 20 mA or 4 to 20 mA Inputs Input 2 1 Connect the copper leads from the calibrat
221. the controller A Input 1 25 R Input 2 eS 22 mA Connections EH Y 26 Connections eS 27 Input 1 XXXX Figure 5 1 Input 1 and Input 2 Wiring Terminals Equipment Needed Table 5 3 lists the equipment you will need to calibrate the specific types of inputs that are listed in the table You will need a screwdriver to connect these devices to your controller Table 5 3 Equipment Needed Type of Input Equipment Needed Thermocouple e A calibrating device with at least 0 02 accuracy for use as a Inputs Ice Bath signal source such as a millivolt source e Thermocouple extension wire that corresponds with the type of thermocouple that will be used with the controller input e Two insulated copper leads for connecting the thermocouple extension wire from the ice baths to the mV source e Two containers of crushed ice Thermocouple e A calibrating device with at least 0 02 accuracy for use as a Inputs T C Source signal source such as a millivolt source e Thermocouple extension wire that corresponds with the type of thermocouple that will be used with controller input 140 UDC2500 Universal Digital Controller Product Manual March 2012 Input Calibration Type of Input Equipment Needed RTD Resistance e Adecade box with at least 0 02 accuracy capable of providing Thermometer stepped resistance values over a minimum range of 0 to 1650 ohms Device with a resolution of 0 001 ohm e Three insul
222. time out period and to select the timer start by either the keyboard RUN HOLD key or Alarm 2 An optional digital input can also be configured to the start the timer The timer display is selectable as either time remaining see TREM or elapsed time see ET Alarm is activated at the end of the time out period When the timer is enabled it has exclusive control of the alarm 1 relay any previous alarm 1 configuration is ignored At time out the timer is ready to be activated again by whatever action has been configured Function Prompts Table 3 7 ALGOR Group Numeric Code 400 Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code The CONTROL ALGORITHM lets you select CTRALG 401 the type of control that is best for your process ON OFF is the simplest control type The ONOF 0 output can be either ON 100 or OFF 0 The Process Variable PV is compared with the setpoint SP to determine the sign of the error ERROR PV SP The ON OFF algorithm operates on the sign of the error signal In Direct Acting Control when the error signal is positive the output is 100 and when the error signal is negative the output is 0 If the control action is reverse the opposite is true An adjustable overlap Hysteresis Band is provided between the on and off states ATTENTION Other prompts affected OUTHYS Ma
223. tion INU Installed Not Used The installed Output 1 2 option is not used for the configured output algorithm type Not Needed Auxiliary Output is Not Needed to provide the desired output algorithm and can be used for another purpose With the proper configuration Auxiliary Output could also be used as a substitute for the Current Output To obtain this output algorithm type with these Output 1 2 Options 1 Configure the OUTALG selection as TIME D 2 Configure Auxiliary Output for OUTPUT and 3 Scale the Auxiliary Output as necessary for the desired output algorithm type For these March 2012 UDC2500 Universal Digital Controller Product Manual 21 Installation selections the Output 1 HEAT and Output 2 COOL signals will be present both on the Auxiliary Output and on the two relays normally used for Time Duplex Wiring the Controller Using the information contained in the model number select the appropriate wiring diagrams from the composite wiring diagram below Refer to the individual diagrams listed to wire the controller according to your requirements See table for callout details Figure 2 4 Composite Wiring Diagram Callout Details 1 AC DC Line Voltage Terminals See Figure 2 5 Output 3 Terminals See Figure 2 8 through Figure 2 14 Output 4 Terminals See Figure 2 8 through Figure 2 14 Outputs 1 and 2 Terminals See Figure 2 8 through Figure 2 14 Input 2 Term
224. to DIS e HOLD program on hold The program termination state function determines the status of the controller upon completion of the program The selections are e LAST controls to last setpoint e FSAF manual mode and failsafe output When enabled this selection allows you to reset the program to the beginning from the keyboard Ramp soak profile example Before you perform the actual configuration we recommend that you draw a Ramp Soak profile in the space provided on the Program Record Sheet Figure 4 4 and fill in the associated information An example of a Ramp Soak Profile is shown in Figure 4 3 Start setpoint is at 200 degrees F March 2012 UDC2500 Universal Digital Controller Product Manual 121 Monitoring and Operating the Controller E ttt tt tt tt Time Hours 01 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 20765 Figure 4 3 Ramp Soak Profile Example Ramp Soak Profile Example STRSEG Start Seg 1 SG4 TI Soak Time 4 1hr ENDSEG End Seg 12 SG5 RP Ramp Time 5 1 hr 30 min RP UNIT Engr Unit for TIME SG6 SP Soak SP 6 250 Ramp PGEND Controller LAST SP SG6 TI Soak Time 6 3 hr 0 min Status STATE Controller HOLD SG7 RP Ramp Time 7 2 hr 30 min State at end TO BEGIN Reset SP DIS SG8 SP Soak SP 8 500 Program PVSTRT Program starts DIS SG8 TI Soak Time 8 0 hr 30 min at PV value RECYCL Number of 2 SG9 RP Ramp Ti
225. total of four relays plus the Second Current Output Relays are internally socketed Resistive Load 2 amps 120 Vac 240 Vac or 30 Vdc Inductive Load coso 0 4 1 amp 130 Vac or 250 Vac Inductive Load L R 7 msec 1 amp 30 Vdc Solid State Relays One or Two Zero crossing type SPST solid state contacts consisting of a triac N O output Internally socketed Resistive Load 1 0 amp 25 C and 120 or 240 Vac 0 5 amp 55 C and 120 or 240 Vac Inductive Load 50 VA 120 Vac or 240 Vac Minimum Load 20 milliamps Open Collector Outputs One or Two Socketed assembly replacing a relay Opto isolated from all other circuits except current output and not from each other Internally powered 30 Vdc Note Applying an external power supply to this output will damage the instrument Maximum Sink Current 20 mA Short circuit current limit 100 mA Current Outputs One or Two These outputs provide a 21 mA dc maximum into a negative or positive grounded load or into a non grounded load Current outputs are isolated from each other line power earth ground and all inputs Outputs can be easily configured via the keyboard for either direct or reverse action and for either 0 to 20 mA or 4 to 20 mA without field calibration The second current output can be used in an Auxiliary Output mode This Auxiliary Output can be configured to represent either Input PV Setpoint Deviation or Control output The range of an Auxiliary Output can be
226. troller in your system 7 7 Troubleshooting Procedures Introduction The troubleshooting procedures are listed in numerical order as they appear in Table 7 4 Each procedure lists what to do if you have that particular failure and how to do it or where to find the data needed to accomplish the task A 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 in the tables that follow e Multimeter Capable of measuring millivolts milliamps and resistance e Calibration sources T C mV Volt etc 168 UDC2500 Universal Digital Controller Product Manual March 2012 Procedure 1 Troubleshooting Service Table 7 5 explains how to troubleshoot power failure symptoms 1 Procedure 2 Table 7 5 Troubleshooting Power Failure Symptoms Step What to do How to do it Check the AC line voltage Make sure the chassis plugs into the rear of the case properly Check the system for Brown outs heavy load switching etc and conformance to installation instructions Change Power board Use a voltmeter to measure the AC voltage across terminals L1 and L2 on the rear terminal panel of the controller Check the earth ground connection Withdr
227. uct Manual 213 Modbus Read Write and Override Parameters plus Exception Codes 10 7 9 Options Table 10 18 lists all the register addresses and ranges or selections for the function parameters in Set up Group Options Table 10 17 Set up Group Options Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Auxiliary 0086 134 INT R W 0 None Output 1 Input 1 2 Input 2 3 PV 4 Deviation 5 Output 6 Setpoint 7 LSP1 8 LSP2 Low Scaling 0031 049 FP R W Within the range of the Factor selected variable in ID 134 High Scaling 0032 050 FP R W Within the range of the Factor selected variable in ID 134 Auxiliary 00EC 236 INT R W 0 4 20 mA Output Range 1 0 20 mA 214 UDC2500 Universal Digital Controller Product Manual March 2012 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Digital Input 0OBA 186 INT 0 None 1 1 To Manual 2 To Local Setpoint 1 3 To Local Setpoint 2 4 To Direct Action 5 To Hold Ramp 6 To PID Set 2 7 To Run Ramp 8 To Begin 9 No I Reset 10 To Manual Failsafe Output 11 Disable Keyboard 12 To Timer 13 Initiate Limit Cycle Tuning 14 Setpoint Initialization SP PV 15 To RSP 16 Manual Latching 17 Output 1 tracks Inp
228. up Numeric Code 1100 Function Prompts Function Prompt Selection or Range of Setting Lower Display Upper Display Numeric Numeric Code Code A1S1TY 1101 ALARM 1 SETPOINT 1 TYPE Select what you want Setpoint 1 of Alarm 1 to represent It can represent the Process Variable Deviation Input 1 Input 2 Output and if you have a model with communications you can configure the controller to alarm on SHED If you have setpoint programming you can alarm when a segment goes ON or OFF Parameter Definition NONE 0 NO ALARM IN 1 1 INPUT 1 IN 2 2 INPUT 2 PROC 3 PROCESS VARIABLE DE 4 DEVIATION OUT 5 OUTPUT NOTE 1 SHED 6 SHED FROM COMMUNICATIONS E ON 7 EVENT ON SP PROGRAMMING E OF 8 EVENT OFF SP PROGRAMMING MAN 9 ALARM ON MANUAL MODE NOTE 2 RSP 10 REMOTE SETPOINT FSAF 11 FAILSAFE PrRT 12 PV RATE OF CHANGE DI 1 13 DIGITAL INPUT 1 ACTUATED NOTE 7 DI 2 14 DIGITAL INPUT 2 ACTUATED NOTE 7 BRAK 15 LOOP BREAK NOTE 4 March 2012 UDC2500 Universal Digital Controller Product Manual 77 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code DE 2 16 DEVIATION FROM LSP 2 NOTE 3 TCW 17 THERMOCOUPLE WARNING NOTE 5 TCF 18 THERMOCOUPLE FAILING NOTE 6 ATTENTION NOTE 1 When the controller is configured for Three Position Step Control alarms set for Output will not function NOTE 2 Alarm 1 is not available if the Ti
229. uple High E L E Thermocouple Low J H J Thermocouple High J M J Thermocouple Med J L J Thermocouple Low K H K Thermocouple High K M K Thermocouple Med K L K Thermocouple Low NNMH Ni Ni Moly Thermocouple High NNML Ni Ni Moly Thermocouple Low NICH Nicrosil Nisil Thermocouple High NICL Nicrosil Nisil Thermocouple Low R R Thermocouple S S Thermocouple T H T Thermocouple High T L T Thermocouple Low W H W5W26 Thermocouple High W L W5W26 Thermocouple Low 100H 100 Ohm RTD High 100L 100 Ohm RTD Low 200 200 Ohm RTD 500 500 Ohm RTD RADH Radiamatic RH RADI Radiamatic RI 0 20 0 to 20 Milliamperes 4 20 4 to 20 Milliamperes 10m 0 to 10 Millivolts 50m 0 to 50 Millivolts 100m 0 to 100 Millivolts 0 5 0 to 5 Volts 1 5 1 to 5 Volts 0 10 0 to 10 Volts TDIF Thermocouple Differential PR PR40 PR20 Thermocouple OONDOARWND 56 UDC2500 Universal Digital Controller Product Manual March 2012 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Numeric Numeric Code Code XMITR1 TRANSMITTER CHARACTERIZATION This selection lets you instruct the controller to characterize a linear input to represent a non linear one If characterization is performed by the transmitter itself then select LIN Linear ATTENTION Prompt only appears when a linear actuation is selected at prompt IN1 TYPE
230. urrent output range of from 0 mA to 21 mA and is usually calibrated at 4 mA for 0 of output and 20 mA for 100 of output or any other values between 0 mA and 21 mA It is not necessary to re calibrate the controller in order to change from 4 to 20 mA operation over to O to 20 mA operation a simple configuration change is all that is required See the AO RANGE configuration in Sub section 3 12 for details Equipment Needed You will need a calibrating device with whatever accuracy is required capable of measuring 0 to 20 mA Calibrator Connections Refer to Figure 6 2 and wire the controller according to the procedure given in Table 6 3 1 Apply power and allow the controller to warm up 30 minutes before you calibrate Table 6 3 Set Up Wiring Procedure for Auxiliary Output 2 Set LOCK in the Tuning Set Up group to NONE 3 Tag and disconnect the field wiring at the rear of the controller from terminals 12 and 13 See Figure 6 2 4 Connect a milliammeter across these terminals Milliammeter Figure 6 2 Wiring Connections for Calibrating Auxiliary Output 156 UDC2500 Universal Digital Controller Product Manual March 2012 Output Calibration March 2012 UDC2500 Universal Digital Controller Product Manual 157 Output Calibration Procedure The procedure for calibrating the auxiliary output is listed in Table 6 4 The numeric codes are also listed Make sure LOCK in the Tuning Set Up group is set to
231. ut 2 18 Start Restart SP Ramp or SP Program Digital Input 00BC 188 INT 0 Disable 1 1 PID2 Combinations 2 Direct 3 LSP2 4 LSP1 5 Run Digital Input OOBB 187 INT Same as Digital Input 1 2 Digital Input 00BD 189 INT Same as Digital Input 1 2 Combinations Combinations x March 2012 Auxiliary Output and Digital Input 2 are mutually exclusive UDC2500 Universal Digital Controller Product Manual 215 Modbus Read Write and Override Parameters plus Exception Codes 10 7 10 Communications Table 10 18 lists all the register addresses and ranges or selections for the function parameters in Set up Group Communications Parameter Description Communications Type Floating Point Byte Order Shed Time Shed Mode and Output Shed Setpoint Recall Computer Setpoint Ratio Comm Data Units 216 Table 10 18 Set up Group Communications Register Address Hex 004F Decimal 79 Data Access Type FP R W INT Data Range or Enumerated Selection Communication 004D 77 1 99 Address 0 None 1 Disable 2 RS 485 Modbus 3 Ethernet IR Port Enable 00F1 241 INT R W 0 Disable 1 Enable Transmit Delay 004E 78 FP R W Response Delay in ms 1 to 500 6ms 0 Big Endian 1 Big Endian Byte Swap 2 Little Endian 3 Little Endian Byte Swap 0 No Shed 1 255 sample periods 0
232. uts are internally powered at 30 Vdc Connecting an external power supply will damage the controller O Alarm 2 is not available with Time Proportional Duplex or Three Position Step Control unless the Dual Relay option is used O Electromechanical relays are rated at 5 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Customer Supplied Solid State relay Output 2 EJ N C Alarm Relay 1 in 9 mu Figure 2 10 Open Collector Output See Table 2 6 for relay terminal connections for other Output Algorithm Types March 2012 UDC2500 Universal Digital Controller Product Manual 27 Installation Time Duplex with a Dual Relay Board 19 Out Relay 2 C N O L1 Out Relay 1 ee Load o Supply Power E E To terminal 4or6 Load _2 Supply Power o LE To terminal 70r9 Dual Electromechanical relays are rated at 2 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Relay Load 7 Alarm N O Relay 1 Relay Load Electromechanical relays are rated at 5 Amps 120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly Use Fast Blo fuses only Figure 2 11 Dual Electromechanical Relay Option Output See Table 2 6 for relay terminal connections for other Output Algorithm Types 19 QH 20 IKRY Current Output Control
233. ve the new code number set repeat steps 1 to 6 Press the FUNCTION Key The instrument will now display XXXX ENTER1 where XXXX is a unique code number for this particular instrument Using the 4 and w keys enter the new Code 1 number Press the FUNCTION Key The instrument will now display XXXX ENTER2 Using the 4 and W keys enter the new Code 2 number Press the FUNCTION Key The instrument will now display XXXX ENTER3 Using the 4 and w keys enter the new Code 3 number Press the FUNCTION Key The instrument will process the new code numbers and add the new software feature If the code numbers were entered incorrectly the controller will go into Manual Mode and flash the message FAILSAFE on the lower display Repeat steps 12 through 16 When the instrument finishes the operation it automatically resets itself and restarts in the product mode The instrument configuration now includes the added software feature s March 2012 UDC2500 Universal Digital Controller Product Manual 179 Parts List 8 Parts List 8 1 Exploded View Introduction Figure 8 1 is an exploded view of the UDC2500 Controller Each part is labeled with a key number The part numbers are listed by key number in Table 8 1 Parts not shown are listed in Table 8 2 Figure 8 1 UDC2500 Exploded View 180 UDC2500 Universal Digital Controller Product Manual March 2012 Parts List Table 8
234. version This will happen 2 Make sure the input is correct and that it has if 5 not burned out opened e Upscale or Downscale A l l burnout is selected and th Check for gross over ranging with a multimeter input is open f Input not configured correctly Restore factory calibration See Subsection for the sensor being used 5 8 March 2012 UDC2500 Universal Digital Controller Product Manual 165 Troubleshooting Service Lower Reason for Failure How to Correct the Problem Display IN2RNG Input 2 out of range The remote input Same as IN1RNG above is outside the range limits IN2_FL Two consecutive failures of input 2 Same as IN1FL above integration i e cannot make analog to digital conversion CNFERR e PV low limit is gt PV high limit 1 Check the configuration for each item and e SP low limit is gt SP high limit reconfigure if necessary e Output low limit gt Output high limit PV LIM PV out of range 1 Make sure the input signal is correct PV INP1 x RATIO1 INP1 BIAS 2 Make sure the Ratio and Bias settings are correct 3 Recheck the calibration Use Bias of 0 0 RV LIM The result of the formula shown below 1 Make sure the input signal is correct is beyond the range of the remote variable 2 Make sure the Ratio2 and Bias2 settings are correct RV INP2 X RATIO BIAS ee 3 Recheck the calibration Use a Ratio2 of 1 0 and a Bias2 of 0 0 SEGERR Setpoint
235. will switch from Tuning Constant Set 2 to Set 1 Value in engineering units within PV or SP range limits ATTENTION Only appears when PID SETS selection is configured for either 2 PVSW or 2 SPSW 2 TWO SETS PV AUTOMATIC SWITCHOVER When the process variable is GREATER than the value set at prompt SW VALUE Switchover Value the controller will use Gain Rate Reset and Cycle Time The active PID SET can be read in the lower display When the process variable is LESS than the value set at prompt SW VALUE the controller will use Gain 2 Rate 2 Reset 2 and Cycle 2 Time The active PID SET can be read in the lower display ATTENTION Other prompts affected SW VALUE 3 TWO SETS SP AUTOMATIC SWITCHOVER When the setpoint is GREATER than the value set at prompt SW VALUE Switchover Value the controller will use Gain Rate Reset and Cycle When the setpoint is LESS than the value set at prompt SW VALUE the controller will use Gain 2 Rate 2 Reset 2 and Cycle 2 ATTENTION Other prompts affected SW VALUE LSP S 803 LOCAL SETPOINT SOURCE This selection determines what your local setpoint source will be ONE 0 LOCAL SETPOINT The setpoint entered from the keyboard March 2012 UDC2500 Universal Digital Controller Product Manual 63 Configuration Function Prompt Selection or Range of Setting Lower Display Upper Display RSPSRC Numeric Numeric Code Code T MS 8 NONE 0 INP2 1
236. x Control Procedure for Using MANUAL TUNE for Heat side of Duplex Control Procedure for Using MANUAL TUNE for Cool side of Duplex Control Procedure for Accessing Accutune Error Codes Accutune Error Codes Set Up Procedure Procedure for Switching PID SETS from the Keyboard Procedure for Displaying Alarm Setpoints Procedure for Displaying 3Pstep Motor Position Procedure for Setting a Failsafe Value Procedure for Setting a Failsafe Mode Running A Setpoint Ramp Program Contents UDC2500 Universal Digital Controller Product Manual Introduction 108 108 109 110 110 112 113 113 114 115 116 117 119 xi Introduction Table 4 26 Run Monitor Functions Table 5 1 Voltage Milliamp and Resistance Equivalents for Input 1 Range Values Table 5 2 Voltage and Milliamp Equivalents for Input 2 Range Values Table 5 3 Equipment Needed Table 5 4 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath Table 5 5 Set Up Wiring Procedure for Thermocouple Inputs using Thermocouple Source Table 5 6 Set Up Wiring Procedure for RTD Inputs Table 5 7 Set Up Wiring Procedure for Radiamatic Millivolts Volts or T C Differential Inputs Table 5 8 Set Up Wiring Procedure for 0 to 10 Volts Table 5 9 Set Up Wiring Procedure for Milliampere Inputs Table 5 10 Input 1 Calibration Procedure Numeric Code 10000 Table 5 11 Set Up Wiring Procedure for 0 to 20 mA or 4 to 20 mA Inputs Input 2 Table 5 12 Set Up Wiring Procedure for 0 to 2 Vo
237. xcept for the Calibration and Keyboard Lockout groups CONFIGURATION Tuning SP Ramp and Accutune groups are read write All other groups are read only Calibration and Keyboard Lockout groups are not available VIEW Tuning and Setpoint Ramp parameters are read write No other parameters are viewable ALL Tuning and Setpoint Ramp parameters are available for read only No other parameters are viewable MANUAL AUTO KEY LOCKOUT Allows AUTOMA you to disable the Manual Auto key DISABLE ENABLE ATTENTION Can only be viewed if LOCKOUT is configured for NONE RUN HOLD KEY LOCKOUT Allows you to disable the Run Hold key for either SP Ramp or SP Program The Run Hold key is never disabled when used to acknowledge a latched alarm 1 or a Diagnostic Message DISABLE ENABLE ATTENTION Can only be viewed if LOCKOUT is configured for NONE SETPOINT SELECT KEY LOCKOUT Allows you to disable the Setpoint Select key DISABLE ENABLE ATTENTION Can only be viewed if LOCKOUT is configured for NONE March 2012 UDC2500 Universal Digital Controller Product Manual 39 Configuration 3 5 SP Ramp Set Up Group Introduction Set Point Ramp Set Point Programs and Set Point Rates can be configured in this group A single Setpoint Ramp SP RAMP can be configured to occur between the current local setpoint and a final local setpoint over a time interval of from 1 to 255 minu
238. xists a replacement controller or part will be shipped with instructions for returning the defective unit Do not return your controller without authorization from Honeywell s Technical Assistance Center or until the replacement has been received Check out Honeywell s web site at http www honeywell com ps Determining the software version Table 7 1 lists the procedure for identifying the software version number Table 7 1 Procedure for Identifying the Software Version sep peraion Press Rem 1 Select C setup Upper Display READ STATUS NEA Lower Display STATUS Set Up Group 2 Read the software Function You will see ersion an SS Upper Display Software version number 32xx Lower Display VERSION Please give this number to the Customer Support person It will indicate which version of UDC2500 you have and help them determine a solution to your problem March 2012 UDC2500 Universal Digital Controller Product Manual 163 Troubleshooting Service 7 3 Power up Tests What happens at power up When power is applied the controller will run three diagnostic tests After these tests are completed TEST DONE is displayed Test Failures If one or more of these tests fail the controller will go to the Failsafe Manual Mode and FAILSF will flash in the lower display and a message indicating which test failed will appear in the lower display Then DONE will appear in the lower display Three Posit

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