Honeywell UDC2500 Operating Manual

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UDC2500

Universal Digital Controller

Limit Control Model

Product Manual

51-52-25-136

March 2007

ii UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

About This Document

Abstract

This document provides descriptions and procedures for the Installation, Configuration, Operation, and Troubleshooting of your UDC2500 Controller.

Symbol Definitions

The following table lists those symbols used in this document to denote certain conditions.

Symbol Definition

This CAUTION symbol on the equipment refers the user to the Product Manual for additional information. This symbol appears next to required information in the manual.

WARNING PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a

potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms, 42.4 Vpeak, or 60 VDC may be accessible. Failure to comply with these instructions

could result in death or serious injury.

ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for handling electrostatic sensitive devices

Protective Earth (PE) terminal. 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.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual iii

1 INTRODUCTION ...................................................................................................1

1.1 Overview.........................................................................................................................................1

1.1.1 Function of keys...................................................................................................................3

1.2 Process Instrument Explorer Software............................................................................................4

1.3 CE Conformity (Europe).................................................................................................................6

2 INSTALLATION.....................................................................................................7

2.1 Overview.........................................................................................................................................7

2.2 Condensed Specifications...............................................................................................................8

2.3 Model Number Interpretation .......................................................................................................11

2.4 Limit and Alarm Relay Contact Information................................................................................13

2.5 Mounting.......................................................................................................................................14

2.6 Wiring...........................................................................................................................................16

2.6.1 Electrical Considerations ...................................................................................................16

2.7 Wiring Diagrams...........................................................................................................................18

2.8 Limit Control Application Diagram..............................................................................................25

3 CONFIGURATION...............................................................................................26

3.1 Overview.......................................................................................................................................26

3.2 Configuration Prompt Hierarchy ..................................................................................................27

3.3 Configuration Procedure...............................................................................................................28

3.4 Lock Set Up Group.......................................................................................................................29

3.5 Limit Set Up Group ......................................................................................................................30

3.6 Input 1 Set Up Group....................................................................................................................31

3.7 Options Set Up Group...................................................................................................................35

3.8 Communications Set Up Group....................................................................................................37

3.9 Alarms Set Up Group....................................................................................................................39

3.10 Display Set Up Group ...............................................................................................................43

3.11 P.I.E. Tool Ethernet and Email Configuration Screens.............................................................45

3.12 Configuration Record Sheet......................................................................................................48

4 OPERATING THE LIMIT CONTROLLER ...........................................................49

4.1 Overview.......................................................................................................................................49

4.2 Operator Interface.........................................................................................................................50

4.3 Entering a Security Code ..............................................................................................................50

4.4 Lockout Feature............................................................................................................................51

4.5 Monitoring Your Limit Controller................................................................................................52

iv UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

4.6 Operating Your Limit Controller..................................................................................................54

4.7 Alarm Setpoints ............................................................................................................................57

4.8 P.I.E. Tool Maintenance Screens..................................................................................................58

4.9 Configuring your Ethernet Connection.........................................................................................64

5 INPUT CALIBRATION.........................................................................................69

5.1 Overview.......................................................................................................................................69

5.2 Minimum and Maximum Range Values.......................................................................................70

5.3 Preliminary Information................................................................................................................72

5.4 Input 1 Set Up Wiring...................................................................................................................73

5.5 Input 1 Calibration Procedure.......................................................................................................78

5.6 Restore Input Factory Calibration.................................................................................................79

6 OUTPUT CALIBRATION.....................................................................................83

6.1 Overview.......................................................................................................................................83

6.2 Auxiliary Output Calibration........................................................................................................83

6.3 Restore Output Factory Calibration..............................................................................................85

7 TROUBLESHOOTING/SERVICE........................................................................87

7.1 Overview.......................................................................................................................................87

7.2 Troubleshooting Aids....................................................................................................................88

7.3 Power-up Tests..............................................................................................................................90

7.4 Status Tests ...................................................................................................................................90

7.5 Background Tests..........................................................................................................................91

7.6 Controller Failure Symptoms........................................................................................................93

7.7 Troubleshooting Procedures .........................................................................................................94

7.8 Restoring Factory Configuration ................................................................................................100

8 PARTS LIST......................................................................................................101

8.1 Exploded View............................................................................................................................101

8.2 Removing the chassis..................................................................................................................103

9 MODBUS RTU FUNCTION CODES..................................................................104

9.1 Overview.....................................................................................................................................104

9.2 General Information....................................................................................................................104

9.3 Function Code 20 (14h) - Read Configuration Reference Data..................................................106

9.3.1 Read Configuration Examples .........................................................................................108

9.4 Function Code 21 (15h) - Write Configuration Reference Data.................................................110

9.4.1 Write Configuration Examples ........................................................................................ 112

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual v

10 MODBUS READ, WRITE AND OVERRIDE PARAMETERS PLUS EXCEPTION

CODES........................................................................................................................113

10.1 Overview.................................................................................................................................113

10.2 Reading Control Data..............................................................................................................115

10.3 Miscellaneous Read Onlys......................................................................................................115

10.3.1 Register Addresses for Read Onlys..............................................................................115

10.4 Configuration Parameters........................................................................................................116

10.4.1 Lock..............................................................................................................................116

10.4.2 Limit.............................................................................................................................117

10.4.3 Input 1...........................................................................................................................118

10.4.4 Options .........................................................................................................................120

10.4.5 Communications...........................................................................................................121

10.4.6 Alarms ..........................................................................................................................122

10.4.7 Display..........................................................................................................................124

10.5 Modbus RTU Exception Codes...............................................................................................125

11 ETHERNET TCP/IP...........................................................................................127

11.1 Overview.................................................................................................................................127

12 FURTHER INFORMATION................................................................................128

12.1 Modbus RTU Serial Communications ....................................................................................128

12.2 Modbus Messaging on TCP/IP................................................................................................128

12.3 How to Apply Digital Instrumentation in Severe Electrical Noise Environments..................128

13 INDEX................................................................................................................129

vi UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Tables

Table 2-1 Condensed Specifications _____________________________________________________ 8 Table 2-2 Limit Relay Contact Information_______________________________________________ 13 Table 2-3 Alarm Relay Contact Information ______________________________________________ 13 Table 2-4 Mounting Procedure_________________________________________________________ 15 Table 2-5 Permissible Wiring Bundling__________________________________________________ 17 Table 2-6 Terminals for connecting a UDC to a MDI Compliant Hub or Switch __________________ 23 Table 2-7 Terminals for connecting a UDC directly to a PC utilizing a straight-through cable________ 23 Table 3-1 Configuration Topics ________________________________________________________ 26 Table 3-2 Configuration Prompt Hierarchy _______________________________________________ 27 Table 3-3 Configuration Procedure _____________________________________________________ 28 Table 3-4 LOCK Group Function Prompts _______________________________________________ 29 Table 3-5 LIMIT Group Function Prompts _______________________________________________ 30 Table 3-6 INPUT 1 Group Function Prompts _____________________________________________ 31 Table 3-7 OPTION Group Function Prompts _____________________________________________ 35 Table 3-8 Communications Group Function Prompts _______________________________________ 37 Table 3-9 ALARMS Group Function Prompts ____________________________________________ 39 Table 3-10 DISPLY Group Function Prompts_____________________________________________ 43 Table 4-1 Procedure to Enter a Security Code_____________________________________________ 51 Table 4-2 Annunciators ______________________________________________________________ 52 Table 4-3 Error Messages_____________________________________________________________ 53 Table 4-4 Using Contact Input Option___________________________________________________ 56 Table 4-5 Procedure for Displaying Alarm Setpoints _______________________________________ 57 Table 5-1 Voltage, Milliamp and Resistance Equivalents for Input 1 Range Values _______________ 70 Table 5-2 Equipment Needed__________________________________________________________ 72 Table 5-3 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath _________________ 73 Table 5-4 Set Up Wiring Procedure for Thermocouple Inputs using Thermocouple Source _________ 74 Table 5-5 Set Up Wiring Procedure for RTD Inputs ________________________________________ 74 Table 5-6 Wiring Connections for Radiamatic, Thermocouple Differential, Millivolts or Volts (Except 0 to 10

Volts) _________________________________________________________________________ 75

Table 5-7 Procedure to determine calibration voltages for Thermocouple Differential input types other than the

Factory Setting __________________________________________________________________ 75

Table 5-8 Set Up Wiring Procedure for 0 to 10 Volts _______________________________________ 76 Table 5-9 Set Up Wiring Procedure for Milliampere Inputs __________________________________ 77 Table 5-10 Input 1 Calibration Procedure ________________________________________________ 78 Table 5-11 Restore Input Factory Calibration _____________________________________________ 80 Table 6-1 Set Up Wiring Procedure for Auxiliary Output____________________________________ 84 Table 6-2 Auxiliary Output Calibration Procedure _________________________________________ 85 Table 6-3 Restore Factory Calibration ___________________________________________________ 86 Table 7-1 Procedure for Identifying the Software Version ___________________________________ 89 Table 7-2 Procedure for Displaying the Status Test Results __________________________________ 90 Table 7-3 Background Tests___________________________________________________________ 91 Table 7-4 Controller Failure Symptoms__________________________________________________ 93 Table 7-5 Troubleshooting Power Failure Symptoms _______________________________________ 95 Table 7-6 Troubleshooting Latching Output Relay Failure ___________________________________ 96 Table 7-7 Troubleshooting Alarm Relay Output Failure _____________________________________ 96 Table 7-8 Troubleshooting a Keyboard Failure ____________________________________________ 97 Table 7-9 Troubleshooting a RS-485 Communications Failure________________________________ 98 Table 7-10 Troubleshooting Auxiliary Output Failure ______________________________________ 99

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual vii

Table 7-11 Restoring Factory Configuration _____________________________________________ 100 Table 8-1 Parts Identification_________________________________________________________ 102 Table 8-2 Parts Not Shown___________________________________________________________ 102 Table 9-1 Integer Parameter Type _____________________________________________________ 105 Table 9-2 Floating Point Parameter Type________________________________________________ 105 Table 9-3 Register Address Format for Function Code 20___________________________________ 107 Table 9-4 Register Address Format for Function Code 21___________________________________ 111 Table 10-1 Control Data Parameters ___________________________________________________ 115 Table 10-2 Miscellaneous Read Onlys__________________________________________________ 115 Table 10-3 Set-up Group Lock ________________________________________________________ 116 Table 10-4 Set-up Group Limit _______________________________________________________ 117 Table 10-5 Set-up Group – Input 1_____________________________________________________ 118 Table 10-6 Set-up Group – Options ____________________________________________________ 120 Table 10-7 Set-up Group – Communications_____________________________________________ 121 Table 10-8 Set-up Group – Alarms ____________________________________________________ 122 Table 10-9 Set-up Group – Display ____________________________________________________ 124 Table 10-10 Modbus RTU Data Layer Status Exception Codes ______________________________ 126

viii UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Figures

Figure 1-1 UDC2500 Operator Interface __________________________________________________ 2 Figure 1-2 Screen capture of Process Instrument Explorer running on a Pocket PC _________________ 4 Figure 1-3 Depiction of infrared communications ___________________________________________ 5 Figure 2-1 Model Number Interpretation_________________________________________________ 12 Figure 2-2 Mounting Dimensions (not to scale)____________________________________________ 14 Figure 2-3 Mounting Method__________________________________________________________ 15 Figure 2-4 Composite Wiring Diagram __________________________________________________ 18 Figure 2-5 Mains Power Supply________________________________________________________ 19 Figure 2-6 Input 1 Connections ________________________________________________________ 20 Figure 2-7 Electromechanical Relay Output ______________________________________________ 21 Figure 2-8 Solid State Relay Output ____________________________________________________ 21 Figure 2-9 Open Collector Output ______________________________________________________ 22 Figure 2-10 RS-422/485 Communications Option Connections _______________________________ 22 Figure 2-11 Ethernet Communications Option Connections __________________________________ 23 Figure 2-12 Auxiliary Output and Digital Inputs Option Connections __________________________ 24 Figure 2-13 Transmitter Power for 4-20 mA — 2 wire Transmitter Using Open Collector Alarm 2 Output24 Figure 2-14 Transmitter Power for 4-20 mA — 2 Wire Transmitter Using Auxiliary Output________ 25 Figure 2-15 Limit Controller Application Diagram_________________________________________ 25 Figure 3-1 Ethernet Configuration Screen ________________________________________________ 45 Figure 3-2 Email Configuration Screen __________________________________________________ 46 Figure 4-1 Operator Interface__________________________________________________________ 50 Figure 4-2 Maintenance Data Menu_____________________________________________________ 58 Figure 4-3 Loop Data Maintenance Screen _______________________________________________ 59 Figure 4-4 Alarm Details Maintenance Screen ____________________________________________ 60 Figure 4-5 Digital Input Details Screen __________________________________________________ 61 Figure 4-6 Status Data Maintenance Screen_______________________________________________ 62 Figure 4-7 Ethernet Status Maintenance Screen____________________________________________ 63 Figure 4-8 IR Communications Address _________________________________________________ 64 Figure 4-9 Configuration Upload in Progress _____________________________________________ 65 Figure 4-10 Ethernet Communications Type Selection ______________________________________ 66 Figure 4-11 Ethernet Communications Address ___________________________________________ 67 Figure 4-12 Configuration Upload in Progress ____________________________________________ 68 Figure 5-1 Input 1 Wiring Terminals ____________________________________________________ 72 Figure 5-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath _____________________ 73 Figure 5-3 Wiring Connections for Thermocouple Inputs Using Thermocouple Source ____________ 74 Figure 5-4 Wiring Connections for RTD (Resistance Thermometer Device) _____________________ 74 Figure 5-5 Wiring Connections for Radiamatic, Millivolts, Volts or Thermocouple Differential (Except 0 to 10

Volts) _________________________________________________________________________ 75

Figure 5-6 Wiring Connections for 0 to 10 Volts___________________________________________ 76 Figure 5-7 Wiring Connections for 0 to 20 mA or 4 to 20 mA Inputs___________________________ 77 Figure 6-1 Wiring Connections for Calibrating Auxiliary Output______________________________ 84 Figure 8-1 UDC2500 Exploded View __________________________________________________ 101

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual ix

1.1 Overview

Function

UDC2500 Limit Controllers accept input signals from any of several types of external sensors such as Thermocouples (T/Cs) and Resistance Temperature Detectors (RTDs). It conditions these signals, as necessary, to derive the equivalent Process Variable (PV) value that drives various circuits in the controller.

The equivalent PV signal is compared with the Limit control set point and any error signal from the differential amplifier de-energizes the coil of an electromechanical, single-pole, dual-throw (SPDT) limit output relay.

When de-energized, the output relay “Locks Out” and remains that way until the PV input signal drops below the High Limit Set Point or goes above the Low Limit Set Point and the controller is reset manually via the keyboard or from a remote location (Contact Input Option).

Introduction

1 Introduction

The contact of the output relay terminates at the rear terminal of the controller to which you make the appropriate field wiring connections.

A flashing “LIMIT” in the lower display indicates that the output relay is de-energized.

Features

• 90 – 264 Vac or 24 Vac/dc Power Supply

• Input/Output Isolation

• Isolated Auxiliary Current Output / Digital Inputs

• Modbus® RS-485 or Ethernet TCP/IP Communications

High Limit Controller

When the PV input signal is below the limit set point, the output relay energizes. If the PV signal exceeds the limit set point, the output relay de-energizes and the flashing “LIMIT” display is turned on.

When the PV signal returns to a value below the limit set point, the controller can be reset manually using the RESET key or Contact Input Option.

Low Limit Controller

When the PV input signal is above the limit set point, the output relay energizes. If the PV signal falls below the limit set point, the output relay de-energizes and the flashing “LIMIT” display is turned on.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 1

Introduction

When the PV signal returns to a value above the limit set point, the controller can be reset manually using the RESET key or Contact Input Option.

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 operating parameters that meet you process control needs now, and change them later to meet new ones.

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 upgraded 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

2 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

1.1.1 Function of keys

Table 1-1 shows each key on the operator interface and defines its function.

Key Function

• Places the controller in the Configuration Set Up group select mode.

SetupSetup

FunctionFunctionFunction

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.

Introduction

Table 1-1 Function of Keys

Lower

Display

Reset

Select

M-A

Run

Hold

• Selects an operating parameter to be shown in the lower display.

MAN-AUTO This function is not available on the Limit Controller. RESET Reset the Limit Relay.

This key does not function on the Limit Controller

• Acknowledges a latched alarm 1.

• Acknowledges Diagnostic Messages.

• Increases the selected parameter value.

• Decreases the selected parameter value.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 3

Introduction

1.2 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

• Create configurations with intuitive software program running on either a Pocket

PC, a Desktop or a laptop computer. ·

• Create/edit configurations live, just connect software to controller via comm port.·

• Create/edit configurations offline and download to controller later via comm. port.·

• Port types available on every UDC2500:·

o infrared,· o RS 485, o Ethernet.·

• Same port types on UDC3200 and UDC3500 allow interconnectivity.

• This software is available in English, Spanish, Italian, German and French.

Figure 1-2 Screen capture of Process Instrument Explorer running on a Pocket

4 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Infrared communications

The infrared connection provides a non-intrusive wireless connection with the instrument and maintains NEMA4X AND IP66 integrity.

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 maintenance 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.

Introduction

Figure 1-3 Depiction of infrared communications

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 5

Introduction

1.3 CE Conformity (Europe)

This product is in conformity with the protection requirements of the following European Council Directives: 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) 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)

73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC

Declaration of Conformity: 51453655

Deviation from the installation conditions specified in this manual, and the special conditions for CE conformity in Subsection with the Low Voltage and

ATTENTION

EMC Directives.

2.1, may invalidate this product’s conformity

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 Universal Digital Limit ControllerProduct Manual 3/07

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 selections, then proceed with installation.

What’s in this section?

The following topics are covered in this section.

2.1 Overview 7

Installation

2 Installation

2.3), and become familiar with your model

TOPIC See Page

2.2 Condensed Specifications 8

2.3 Model Number Interpretation 11

2.4 Control and Alarm Relay Contact Information 13

2.5 Mounting 14

2.6 Wiring 16

2.7 Wiring Diagrams Composite Wiring Diagram AC Line Voltage Input 1 Connections

18 18 19

20 Relay Output Electromechanical Solid State Open Collector 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

2.8 Limit Control Application Diagram 25

3/07 UDC2500 Universal Digital Limit ControllerProduct 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.

• Inspect the unit for any obvious shipping damage and report any damage due to

transit to the carrier.

• Make sure a bag containing mounting hardware is included in the carton with the

controller.

• Check that the model number shown on the inside of the case agrees with what you

have ordered.

2.2 Condensed Specifications

We recommend that you review and adhere to the operating limits listed in Table 2-1 when you install your controller.

Table 2-1 Condensed Specifications

Analog Inputs

Analog Input Signal Failure Operation

Stray Rejection Common Mode

Digital Inputs (One) (Optional)

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 ohms 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

Burnout Selections: Upscale, Downscale Thermocouple Health: Good, Failing, Failure Imminent or Failed

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 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)

+30 Vdc source for external dry contacts or isolated solid state contacts. Digital Inputs are isolated from line power, earth ground, analog inputs and all outputs except for the Second Current Output.

8 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Installation

Controller Output Types

Alarm Outputs (Optional)

Isolation (Functional)

RS422/485 Modbus RTU Communications Interface (Optional)

Ethernet TCP/IP Communications Interface (Optional)

Infrared Communications (Optional)

Power Consumption

Power Inrush Current

Electromechanical Relay

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 Inductive Load (L/R = 7 msec): 3.5 amps @ 30 Vdc Motor: 1/6 H.P.

Solid State Relay

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

One or two SPDT Electromechanical relays.

Up to four setpoints are independently set as high or low alarm, two for each relay. Setpoint can be on Process Variable, Deviation, PV Rate, Communication Shed or Thermocouple Health. A single adjustable hysteresis of 0.0 to 100.0% is provided.

Alarm Relay Contacts Rating: Resistive Load: 5 amps at 120 Vac or 240 Vac or 30 Vdc

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.

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.

Type: 10Base-T Length of Link: 330 ft. (100 m) maximum Link Characteristics: Four-wire, 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

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

20 VA maximum (90 to 264 Vac) 15 VA maximum (24 Vac/dc)

10A maximum for 4 ms (under operating conditions), reducing to a maximum of 225 mA (90 to 264 Vac operation) or 750 mA (24 Vac/dc operation) after one second.

CAUTION

power is supplied. Otherwise, the instruments may not start up normally due to voltage drop from the inrush current.

= 0.4): 3 amps @ 130 Vac or 250 Vac

When applying power to more than one instrument, make sure that sufficient

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 9

Installation

Weight

3 lbs. (1.3 kg)

Environmental and Operating Conditions

Parameter Reference Rated Operative

Ambient Temperature

Relative Humidity Vibration

Frequency (Hz) Acceleration (g)

Mechanical Shock

Acceleration (g) Duration (ms))

Line Voltage (Vdc) Line Voltage (Vac)

90 to 240 Vac

24 Vac Frequency (Hz)

(For Vac)

25 ± 3 °C 77 ± 5 °F

10 to 55* 10 to 90* 5 to 90* 5 to 95*

0 0

+24 ± 1 22 to 27 20 to 27 - -

120 ± 1 240 ± 2

24 ± 1 50 ± 0.2

60 ± 0.2

15 to 55 °C 58 to 131 °F

0 to 70

0.4

1 30

90 to 240

20 to 27 49 to 51

59 to 61

Limits

0 to 55 °C 32 to 131 °F

0 to 200

0.6

5 30

90 to 264

20 to 27 48 to 52

58 to 62

Transportation and

Storage

–40 to 66 °C –40 to 151 °F

0 to 200

0.5

20 30

- -

* 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.

10 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

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.

KEY NUMBER - UDC2500 Single Loop Controller

Digital Controller for use with 90 to 264Vac Power DC2500 Digital Controller for use with 24Vac/dc Power DC2501

TABLE I - Specify Contro l Output and/or Alarms Selection

Description

Selection

Availability

DC2500 2501

Output #1

Output #2 and Alarm #1 or Alarms 1 and 2

TABLE II - Communications and Software Selections

Communications

Software Selections

Reserved

Infrared interface

TABLE III - Input 1 can be changed in the field using external resistors Selecti o n

Input 1

Input 2

Electro Mechanical Relay (5 Amp Form C) Solid State Relay (1 Amp) Open Collector transistor output

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)

None Auxiliary Output/Digital Inputs (1 Aux and 1 DI or 2 DI) RS-485 Modbus Plus Auxiliary Output/Digital Inputs

Base-T Ethernet (Modbus RTU) Plus Auxiliary Output/Digital Inputs 3 _ _ _

Limit Controller No Selection None Infrared Interface Included (Can be used with a Pocket PC)

TC, RTD, mV, 0-5V, 1-5V TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA, 0-10V None

Selection

TABLE IV - Options

Approvals

2.4 Limit and Alarm Relay Contact Information

Limit Relay

ATTENTION

The Limit relay is designed to operate in a Failsafe mode. This results in momentary (5 seconds maximum) limit action when power is initially applied, until the unit completes selfdiagnostics. If power is lost to the unit, the Limit Control Relay will still function.

Table 2-2 Limit Relay Contact Information

Installation

Power

Off

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.

Power

Limit

Control

Relay

Wiring

N.O. Open Open N.C. Closed N.O. Closed Open N.C. Open

Variable NOT in Limit State Variable in Limit State Unit

Relay

Contact

Indicators Relay

Contact

Off

Closed

Off

Closed

Table 2-3 Alarm Relay Contact Information

Alarm Relay

Wiring

Variable NOT in Alarm State Variable in Alarm State Unit

Relay

Contact

Indicators Relay

Contact

Indicators

Off

Indicators

Off

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 13

N.O. Open Open N.C. Closed N.O. Closed Open N.C. Open

Off

Closed

Off

Closed

Off

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.

• Overall dimensions and panel cutout requirements for mounting the controller are

shown in

• 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.

• The front panel is moisture rated NEMA3 and IP55 rated and can be easily upgraded

to NEMA4X and IP66.

Overall Dimensions

mm inches

Figure 2-2.

Max. panel thickness 19,1 .75

9,0 0,35

92,0 + 0,8

-0,00

3,62 + 0,03

-0,00

Panel Cutout

92,0 + 0,8

-0,00

3,62 + 0,03

-0,00

Figure 2-2 Mounting Dimensions (not to scale)

17,9 0,70

113,1 4,45

90,6 3,57

108,6 4,28

14 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

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.

Attach screws and washers here for water protection

Installation

Mounting Clips

Mounting Procedure

Step Action

Mark and cut out the controller hole in the panel according to the dimension

information in Orient the case properly and slide it through the panel hole from the front.

Remove the mounting kit from the shipping container and install the kit as follows:

• 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 (

• 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 (

• Tighten screws to 2 lb-inch (22 N•cm) to secure the case against the panel. CAUTION: Over tightening will cause distortion and the unit may not seal properly.

For water-protected installations, install four screws with washers into the four

recessed areas in the corners of the bezel ( through the center piercing the elastomeric material and then tighten screws to 5 lb-in (56 N•cm).

Figure 2-3 Mounting Method

Table 2-4 Mounting Procedure

Figure 2-2.

Figure 2-3).

Figure 2-3). Push the point of the screw

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 15

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. Conformity 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 264 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 90-264 Vac applications; or 1 A, 125 V fuse or circuit breaker for 24 Vac/dc applications, as part of the installation. The switch or circuitbreaker shall be located in close proximity to the controller,

OPERATOR. The switch or circuit-breaker shall be marked as the disconnecting device

for the controller.

CAUTION

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.

Applying 90-264 Vac to an instrument rated for 24 Vac/dc will severely

damage the instrument and is a fire and smoke hazard.

within easy reach of the

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, 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 (>30 Vac, 42.4 Vpeak, or 60 Vdc) wiring per Permissible Wiring Bundling,

16 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Table 2-5.

Electrical Noise Precautions

Electrical noise is composed of unabated electrical signals which produce undesirable effects in measurements and control circuits.

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:

• Separate External Wiring—Separate connecting wires into bundles

(See Permissible Wiring Bundling 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 Electrical Noise Environments.

Permissible Wiring Bundling

Installation

Table 2-5) and route the individual bundles

Table 2-5 Permissible Wiring Bundling

Bundle No. Wire Functions

2 Analog signal wire, such as:

• Line power wiring

• Earth ground wiring

• Line voltage control relay output wiring

• Line voltage alarm wiring

• Input signal wire (thermocouple, 4 to 20 mA, etc.)

• 4-20 mA output signal wiring

Digital input signals

• Low voltage alarm relay output wiring

• Low voltage wiring to solid state type control circuits

• Low voltage wiring to open collector type control circuits

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 17

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 can be found on the outside of the case.

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.

uxiliary Output

and Digital Inputs

Terminals

See Figure 2-17

AC Line Voltage

Terminals

See Figure 2-5

Outputs 3 and 4

Terminals

See Figures 2-8

through 2-14

See Figures 2-15 and 2-16

L1 L2/N

4 5 6 7 8 9

Communications

Terminals

10 11

12 13 14 15 16 17

19 20 21

22 23

24 25

26 27

Limit Relay

Terminals

See Figures 2-8

through 2-14

Not

Used

Input #1

Terminals

See Figure 2-6

xxxx

Figure 2-4 Composite Wiring Diagram

18 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Installation

C/DC

Line

Voltage

PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is

Ground

Neutral

Hot

L2/N

4 5 6

7 8 9

12 13

14 15 16 17

19 20 21 22 23 24 25 26 27

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.

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 circuitbreaker for 90-264 Vac applications; or 1 A, 125 V fuse or circuit breaker for 24 Vac/dc applications, as part of the instal lat ion.

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.

xxxx

Figure 2-5 Mains Power Supply

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 19

Installation

Input #1

Millivolt or Volts

–

Xmitter

RTD

Power

Supply

250

except 0-10 Volts

2627+

–

source

mV or

Volt

source

+ –

Thermocouple Differential

Use Thermocouple

–+

extension wire only

R + –

+ –

– +

Thermocouple

Use Thermocouple extension wire only

+ –

0-10 Volts Milliamps

25 26

R +

–

100K

0–10

Volt

source

100K

–

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.

R +

–

+ –

xxxx

Figure 2-6 Input 1 Connections

20 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

N.C.

N.O.

Output

Relay#1

L2/N

Load Supply Power

Electromechanical relays are rated at Amps @120 Vac or 30 Vdc and 2.5 Amps at 240 Vac.

Customer should size fuses accordingly. Use Fast Blo fuses only.

Relay Load

To terminal

Relay Load

To terminal

4 or 6

7 or 9

5 6 7 8 9

N.C. N.O.

larm

Relay#2

larm

Relay#1

Figure 2-7 Electromechanical Relay Output

19 20 21 22 23 24 25 26 27

Installation

Relay Load

To terminal

19 or 21

Load Supply Power

xxxx

Load Supply Power

Dummy Resistor

Output

Relay#1

L2/N

Relay Load

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 30 Vdc and 2.5 Amps at 240 Vac. Customer should size fuse s accordingly. Use Fast Blo fuses only.

To terminal

4 or 6

To terminal

7 or 9

5 6 7 8 9

N.C.

Relay#2

N.O.

N.C. N.O.

Relay#1

larm

N.O.

20 21 22 23 24 25 26 27

Relay Load

Figure 2-8 Solid State Relay Output

Load Supply

Power

xxxxx

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 21

Installation

Load Supply Power

Relay Load

Load Supply Power

CAUTION

Electromechanical relays are rated at 5 Amps @120 Vac or 30 Vdc and 2.5 Amps at 240 Vac. Customer should size fuses accordingly. Use Fast Blo fuses only.

Relay Load

Open collector outputs are internally powered at +30 Vdc. Connecting an external power supply will damage the controller.

To terminal

4 or 6

To terminal

7 or 9

Time Simplex

Output #1

L2/N 4 5 6 7 8 9

N.C. N.O.

larm

Relay#2

larm

Relay#1

Customer Supplied

20 21

–

22 23 24 25 26 27

+ –

Customer Supplied Solid-State relay

Electromechanical relay

–

xxxx

Figure 2-9 Open Collector Output

COMMUNICATION MASTER

SHLD D– (A)

D+ (B)

16 SHLD 17 D+ (B)

18 D– (A)

SHLD

D+

D–

120 OHMS

Connect shield

TO OTHER

COMMUNICATION

CONTROLLERS

D+D–

120 OHMS ON LAS T LEG

Do not run the communications lines in the same conduit as AC power.

Use shielded twisted pair cables (Belden 9271 Twinax or equivalent).

to ground at one end only.

xxxx

Figure 2-10 RS-422/485 Communications Option Connections

22 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

COMMUNICATION MASTER

OR SWITCH

TXD+ TXD-

RXD–

TXD+ TXD-

RXD–

RXD-

TXD+

RXD-

TXD+

RXD+SHLD

TXD–SHLD

RXD+SHLD

TXD–SHLD

14 SHLD

14 SHLD 15 RXD +

15 RXD +

15 RXD+

–

16 RXD

16 RXD-

17 TXD +

17 TXD+

–

18 TXD-

18 TXD

Do not run the communications lines in the same conduit as AC

power. Correct connections may require the use of an Ethernet

power. Correct connections may require the use of an Ethernet cross-over cable.

cross-over cable.

cross-over cable. Use Shielded twisted-pair, Category 5 (STP CAT5) Ethernet cable.

Use Shielded twisted-pair, Category 5 (STP CAT5) Ethernet cable.

Use Switch rather than Hub to maximize performance.

RXD

333

Figure 2-11 Ethernet Communications Option Connections

Installation

Figure 2-11 and Table 2-6 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.

Table 2-6 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 TXDPosition 16 RXD+ 3 TXD+ Position 17 TXD- 2 RXDPosition 18 TXD+ 1 RXD+

Table 2-7 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 2-7 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 TXDPosition 16 RXD+ 1 TXD+ Position 17 TXD- 6 RXDPosition 18 TXD+ 3 RXD+

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 23

Installation

_ A

Auxiliary Output

Connect shield to ground at one end only.

uxiliar

Load

0 - 1000

10 11 12 13

Digital Inputs

Connect shield to ground at one end only.

Digital

Input #1

Figure 2-12 Auxiliary Output and Digital Inputs Option Connections

xxxx

2 Wire Transmitter

5 +

250

6 -

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.

Configure:

2S1TY = NONE 2S2TY = NONE

26 + 27 -

INPUT 1OUTPUT 3

xxxx

Figure 2-13 Transmitter Power for 4-20 mA — 2 wire Transmitter Using Open

Collector Alarm 2 Output

24 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Installation

2 Wire Transmitter

250

12 +

13 -

UXILIARY OUTPUT

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 2-14 Transmitter Power for 4-20 mA — 2 Wire Transmitter

Using Auxiliary Output

2.8 Limit Control Application Diagram

Configure: AUXOUT = OUT

uxiliary Output Calibration ZEROVAL = 4095 SPANVAL = 4095

26 + 27 -

INPUT 1

xxxx

Limit Controller Wiring

Figure 2-15 shows the RIGHT and WRONG way to wire your Limit Controller.

PROCESS

CONTROLLER

POWER

The Limit Controller against a failure of the Control relay

WRONG RIGHT

PROCESS

CONTROLLER

CONTROL

LOAD

RELAY/

SOLENOID

CAN

The Limit Controller against a failure of the Control relay

LOAD

CANNOT

LIMIT

CONTROLLER

CONTROL

RELAY/ SOLENOID

protect

POWER

LIMIT

CONTROLLER

protect

Figure 2-15 Limit Controller Application Diagram

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 25

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?

3 Configuration

The following topics are covered in this section.

Table 3-1 Configuration Topics

TOPIC See Page

3.1 Overview 26

3.2 Configuration Prompt Hierarchy 27

3.3 Configuration Procedure 28

3.4 Tuning Set Up Group 29

3.5 Limit Set Up Group 30

3.6 Input 1 Set Up Group 31

3.7 Options Set Up Group 35

3.8 Communications Set Up Group 37

3.9 Alarms Set Up Group 39

3.10 Display Set Up Group 43

3.11 P.I.E. Tool Ethernet and Email Configuration Screens 45

3.12 Configuration Record Sheet 48

26 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

3.2 Configuration Prompt Hierarchy

Table 3-2 Configuration Prompt Hierarchy

Set Up Group Function Prompts

Configuration

LOCK LIMIT

INPUT1

OPTIONS

COM

ALARMS

DISPLY

STATUS

SECUR LOCK

LOorHI POWRUP SPMAX SPMIN DISPLY

IN1TYP XMITR1 IN1 HI IN1 LO BIAS 1 FILTR1 BRNOUT EMISS

DIGIN1 AUXOUT

ComADR ComSTA IRENAB BAUD SDENAB SHDTIM BAUD TX DLY

WS FLT UNITS LOOPBK

A1S1TY A1S1VA A1S1HL A1S1TY A1S1VA A1S1HL A1S1TY A1S1VA

A1S1HL A1S1TY A1S1VA A1S1HL ALHYST ALARM1 BLOCK DIAGAL

DECMAL UNITS FREQ LWRDSP TCDIAG

VERSON FAILSF TESTS

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 27

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 Section If you want to change any of these selections or values, follow the procedure in 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,

or keys will move group prompts forward or backward at a rate twice as fast.

Table 3-3 Configuration Procedure

Step Operation Press Result

Enter Set Up

Mode

Select any Set

Up Group

Select a Function

Parameter

Change the

Value or

Selection

Enter the Value

or Selection

Exit Configuration

SetupSetup

FunctionFunctionFunction

Lower

Display

Upper Display = SET Lower Display = LOCK (This is the first Set Up Group title)

Sequentially displays the other Set Up group titles shown in the prompt hierarchy in Hierarchy

You can also use the 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.

Upper Display = the current value or selection for the first

Lower Display = the first Function prompt within that Set Up

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.

Increments or decrements the value or selection that appears for the selected function prompt. If you change the value or selection of a parameter while in Set Up mode then decide not to enter it, press M-A/RESET once—the original value or selection is recalled.

Enters value or selection made into memory after another 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.

3.12.

Table 3-2 Configuration Prompt

or keys to scan the Set Up

function prompt of the selected Set Up group.

group.

Table

28 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

3.4 Lock Set Up Group

Introduction

The Lock Set Up group contains the Function parameters that will allow your controller to protect Configuration and Calibration data.

Because this group contains functions that have to do with Security and Lockout, it is best to configure this group last, after all the other configuration data has been loaded.

Function Prompts

Table 3-4 LOCK Group Function Prompts

Configuration

Function Prompt

Lower Display

SECUR

LOCK

Selection or Range of Setting

Upper Display

0 to 4095 When “LOCK” is configured as “NONE”, the

Security Code number is displayed and can be changed using the raise/lower keys

NONE CAL

CONF

+SP

NONE – all parameters are read/write CAL - all parameters are read/write except

Calibration CONF – configuration parameters are Read

Only; no writes permitted +SP – Only the Lockout group is available for

read/write. Setpoint value is Read Only.

Parameter

Definition

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 29

Configuration

3.5 Limit Set Up Group

Introduction

This data deals with the type of Limit Control you want, power up Logic, setpoint high and low limits, and the default display function Prompts

Table 3-5 LIMIT Group Function Prompts

Function Prompt

Lower Display

LOorHI

POWRUP

SP_MAX

Selection or Range of Setting

Upper Display

LOW

HIGH

RST

NORM

0 % to 100 % of input in engineering units

Parameter

Definition

LOW - Limit Control - latching relay deenergizes when PV goes below configured setpoint; cannot be reset until PV rises above configured setpoint and M-A RESET key is pressed.

HIGH - Limit Control - latching relay deenergizes when PV goes above configured setpoint; cannot be reset until PV drops below configured setpoint and M-A RESET key is pressed.

RST - after power down, the controller latching relay will have to be reset.

NORM - after power down, the controller will operate normally in the same mode as before power was removed unless a limit has been exceeded. If the limit was latched at power down, the unit will be in “Limit” at power up and have to be reset.

HIGH SETPOINT LIMIT - this selection prevents the setpoint from going above the value selected here. The setting must be equal to or less than the upper range of the input.

SP_MIN

DISPLY

0 % to 100 % of input in engineering units

PROC

LOW SETPOINT LIMIT - this selection prevents the setpoint from going below the value selected here. The setting must be equal to or greater than the lower range of the input.

PROC - Process Variable - PV will be displayed in the upper display.

SP - Setpoint - if configured the setpoint will be displayed in the upper display. “SP” will appear in the lower display.

30 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

3.6 Input 1 Set Up Group

Introduction

This data deals with various parameters required to configure Input 1.

Function Prompts

Table 3-6 INPUT 1 Group Function Prompts

Configuration

Function Prompt

Lower Display

IN1TYP

Selection or Range of Setting

Upper Display

B E H E L J H J M J L K H K M K L NNMH NNML NICH NICL R S T H T L W H W L 100H 100L 200 500 RADH RADI 0-20 4-20 10m 50m 100m 0-5 1-5 0-10 TDIF PR

Parameter

Definition

INPUT 1 ACTUATION TYPE – This

selection determines what actuation you are going to use for Input 1.

B—B Thermocouple E H—E Thermocouple 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

* These input types are not available on FM Models.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 31

Configuration

Function Prompt

Lower Display

XMITR1

Selection or Range of Setting

Upper Display

B E H E L J H J M J L K H K M K L NNMH NNML NICH NICL R S T H T L W H W L 100H 100L 200 500 RADH RADI LIN SrT

Parameter

Definition

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.

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).

Parameter definitions are the same as in IN1 TYPE.

ATTENTION Not available on FM Models.

IN1 HI

−999 to 9999 floating in engineering units

INPUT 1 HIGH RANGE VALUE in engineering units is displayed for all inputs but can only be configured for linear or square root transmitter characterization.

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 0 Then 20 mA = 250 Liters/Minute and 4 mA = 0 Liters/Minute

ATTENTION The range of the Limit setpoint will be limited by the range of units selected here.

32 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Configuration

Function Prompt

Lower Display

IN1 LO

BIAS 1

FILTR1

Selection or Range of Setting

Upper Display

−999 to 9999 floating in engineering units

−999 to 9999 floating in engineering units for Non-FM Models

-10 to 10 floating in engineering units for FM Models

0 to 120 seconds 0 = No Filter

Parameter

Definition

INPUT 1 LOW RANGE VALUE in

engineering units is displayed for all inputs 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.

ATTENTION The control setpoint for Input 1 will be limited by the range of units selected here.

BIAS ON INPUT 1 — 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 1.

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.

BRNOUT

DOWN

BURNOUT PROTECTION (SENSOR BREAK) provides most input types with

upscale or downscale protection if the input fails.

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.

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.

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 0 mA (i.e., within the normal operating range) when the 0-20 mA line is opened.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 33

Configuration

Function Prompt

Lower Display

EMISS

Selection or Range of Setting

Upper Display

0.01 to 1.00

Parameter

Definition

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 radiator. Available only for Radiamatic inputs.

34 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

3.7 Options Set Up 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 Prompts

Table 3-7 OPTION Group Function Prompts

Configuration

Function Prompt Selection or Range of Setting

Lower Display Upper Display

AUXOUT

NONE PROC

DEV

Parameter

Definition

AUXILIARY OUTPUT SELECTION

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.

NO AUXILIARY OUTPUT PROCESS VARIABLE—Represents the

value of the Process Variable. PV = Input XxRatioX + BiasX

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 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%

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 35

Configuration

Function Prompt Selection or Range of Setting

Lower Display Upper Display

0_PCT

Value in Engineering Units

AUXILIARY OUTPUT LOW SCALING

Parameter

Definition

FACTOR—Use a value in engineering units

to represent all AUX OUT parameters except output.

Use value in percent (%) for output. (Output can be between –5 % and +105 %.)

100 PCT

Value in Engineering Units

AUXILIARY OUTPUT HIGH SCALING FACTOR—Use a value in engineering units

to represent all AUX OUT parameters except output.

Use a value in percent (%) for Output. (Output can be between –5 % and +105 %.)

CRANGE AUXILIARY OUTPUT RANGE allows the

4-20 0-20

user to easily select 4-20mA output or 020mA 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

DIS ENAB

DIGITAL INPUT 1 SELECTIONS—All selections are available for Input 1. The controller returns to its original state when contact opens, except when overruled by the keyboard.

EXTERNAL RESET (DIGITAL INPUT) — resets the latching relay on contact closure.

DIS – Disable ENAB – Enable

36 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

3.8 Communications Set Up Group

Introduction

The Communications group lets you configure the controller to be connected to a host computer via Modbus® or Ethernet TCP/IP protocol.

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 communications 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.

ATTENTION

FM Models cannot have parameters changed (write transactions) via communications, parameters can only be changed via the keyboard.

Configuration

Function Prompts

Table 3-8 Communications Group Function Prompts

Function Prompt Selection or Range of

Lower Display

ComADR COMMUNICATIONS STATION ADDRESS—This

COMSTA

IRENAB INFRARED COMMUNICATIONS –

BAUD

1 to 99

DIS MODB ETHR

DIS EnAB

4800 9600 19200 38400

Setting

Upper Display

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 ETHERN—Enable Ethernet communications

Enables/Disables the IR Port. BAUD RATE is the transmission speed in bits per

second.

4800 BAUD 9600 BAUD 19200 BAUD 38400 BAUD

Parameter

Definition

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 37

Configuration

Function Prompt Selection or Range of

Lower Display

Setting

Parameter

Definition

Upper Display

TX_DLY TX DELAY—Configurable response-delay timer allows

WS_FLT

1 to 500 milliseconds

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.

Defines word/byte order of floating point data for communications. Byte values:

0 1 2 3 seeeeeee emmmmmmm mmmmmmmm mmmmmmmm

FP B FPBB FP L FPLB

SDENAB SHED ENABLE—Disables/enables shed

DIS EnAB

Where: s = sign, e = exponent, m = mantissa bit

0 1 2 3 1 0 3 2 3 2 1 0 2 3 0 1

functionaliy.

SHDTIM SHED TIME—The number that represents how many

UNITS

LOOPBK LOCAL LOOPBACK tests the communications

0 to 255 Sample Periods

PCT EGR

sample periods there will be before the 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.

PERCENT ENGINEERING UNITS

hardware.

DIS ENAB

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 will 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.

38 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

3.9 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.

Configuration

Function Prompts

Table 3-9 ALARMS Group Function Prompts

Function Prompt Selection or Range of Setting

Lower Display Upper Display

A1S1TY

ATTENTION

NONE PROC DE SHED FSAF PrRT DI TC W TC F

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.

NO ALARM PROCESS VARIABLE DEVIATION SHED FROM COMMUNICATIONS FAILSAFE PV RATE OF CHANGE DIGITAL INPUT 1 ACTUATED THERMOCOUPLE WARNING (NOTE 1) THERMOCOUPLE FAILING (NOTE 2)

NOTE 1. Thermocouple Warning means that the instrument has detected that the Thermocouple Input is starting to fail. Not valid for input types other than Thermocouple.

Parameter

Definition

NOTE 2. Thermocouple Failing means that

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 39

the instrument has detected that the

Configuration

Function Prompt Selection or Range of Setting

Lower Display Upper Display

Parameter

Definition

Thermocouple Input is in imminent danger of failing. Not valid for input types other than Thermocouple.

A1S1VA

Value in engineering units

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.

This prompt does not appear for Alarm Types that do not use values. For example: A1S1TY = MANUAL.

A1S1HL ALARM 1 SETPOINT 1 STATE—Select

A1S2TY ALARM 1 SETPOINT 2 TYPE—Select what

HIGH LOW

whether you want the alarm type chosen in prompt A1S1TYPE to alarm High or Low.

HIGH ALARM LOW ALARM

you want Setpoint 2 of Alarm 1 to represent. The selections are the same as A1S1TYPE.

A1S2VA

Value in engineering units

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.

A1S2HL

HIGH LOW

A2S1TY ALARM 2 SETPOINT 1 TYPE—Select what

ALARM 1 SETPOINT 2 STATE—Same as

A1S1HL.

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.

A2S1VA

Value in engineering units

ALARM 2 SETPOINT 1 VALUE—This is the value at which you want the alarm type chosen in prompt A2S1TYPE to actuate.

The details are the same as A1S1 VAL.

A2S1HL ALARM 2 SETPOINT 1 STATE—Same as

HIGH LOW

A1S1HL.

40 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Configuration

Function Prompt Selection or Range of Setting

Lower Display Upper Display

A2S2TY ALARM 2 SETPOINT 2 TYPE—Select what

Value in engineering units

Parameter

Definition

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.

A2S2VA

ALARM 2 SETPOINT 2 VALUE—This is the

value at which you want the alarm type chosen in prompt A2S2TYPE to actuate.

The details are the same as A1S1 VAL.

A2S1HL

ALHYST

HIGH LOW

0.0 to 100.0 % of span or full output as appropriate

ALARM 2 SETPOINT 1 STATE—Same as A1S1HL.

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.

ALARM1

NO LAT LATCH

Configure the hysteresis of the alarm based on OUTPUT signals as a % of the full scale output range.

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.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 41

Configuration

Function Prompt Selection or Range of Setting

Lower Display Upper Display

BLOCK ALARM BLOCKING—Prevents nuisance

DIS AL1 AL 2 AL12

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 AL 1—Blocks alarm 1 only AL 2—Blocks alarm 2 only AL12—Blocks both alarms

Parameter

Definition

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).

DIAGAL DIAGNOSTIC—Monitors the Current Output

DIS AL 1 AL 2 DISWRN

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 is diagnostic alarm DISABLE WARNING—Disables Output Fail message on lower display

42 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

3.10 Display Set Up Group

Introduction

This group includes selections for Decimal place, Units of temperature, Language and Power frequency.

Function Prompts

Table 3-10 DISPLY Group Function Prompts

Configuration

Function Prompt Selection or Range of Setting

Lower Display Upper Display

DECMAL

UNITS

FREQ

NONE ONE

TWO

F C NONE

60 50

Parameter

Definition

DECIMAL POINT LOCATION—This

selection determines where the decimal point appears in the display.

NONE—No Decimal Place—fixed, no autoranging

ONE—888.8 TWO—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 DEG C—Degrees Centigrade NONE—No display of units

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 can cause normal mode noise problems in the input readings.

LWRDSP

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 43

ENAB DIS

LOWER DISPLY—Select whether the unit uses single or dual display.

ENAB—Enable Dual Display DIS—Disable Dual Display (Single Display Only)

Configuration

Function Prompt Selection or Range of Setting

Lower Display Upper Display

TCDIAG

ENAB DIS

Parameter

Definition

THERMOCOUPLE DIAGNOSTICS—Enable

or disable Thermocouple diagnostic messages.

ENAB—Enable Diagnostic Messages DIS—Disable Diagnostic Messages

44 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

3.11 P.I.E. Tool 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.I.E.

Tool

). The figures in this section show screen-shots of the Configuration Screens from the PC version of the P.I.E. Tool 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.

. Pocket PC Configuration Screens are generally

Configuration

These settings can be changed via the Ethernet Configuration Screen as shown in 3-1

See Section

4.9 – Configuring your Ethernet Connection for more information.

Figure

Figure 3-1 Ethernet Configuration Screen

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 45

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” to match the setting that is now in your controller.

Email Configuration Screen

This controller may be configured to support up to two Emails. Each Email can be sent to a different address. Emails are sent only when the selected alarm transitions from the OFF to the ON state.

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 generally be found by opening a DOS shell and typing:

ping smtp.[your domain name and extension], i.e., “ping smtp.your_isp.com”

46 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

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.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 47

Configuration

3.12 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.

Group Function Value or Factory Group Function Value or Factory

Prompt Prompt Selection Setting Prompt Prompt Selection Setting

LOCK

LIMIT

INPUT1

OPTIONS

SECUR LOCK

LOW or HIGH POWRUP SP MAX SP MIN DISPLY

IN1TYP XMITR1 IN1 HI IN1 LO BIAS 1 FILTR1 BRNOUT EMIS FREQ DISPLY

AUXOUT 0 PCT 100 PCT CRANGE DIGIN1

_______ _______

_______ _______ _______ _______ _______ _______

_______ _______ _______ _______ _______ _______ _______ _______ _______ _______

_______ _______ _______ _______ _______

DIS CAL

HIGH NORM 1000 0 PROC

KH LIN 2400

1.00

0.0

1.0 UP

1.0 60 SP

DIS 0 100 4-20 DIS

COM

ALARMS

ComADR ComSTA IRENAB SDENAB SHDTIM BAUD TX DLY WS FLT UNITS LOOPBK

A1S1TY A1S1VA A1S1HL A1S2TY A1S2VA A1S2HL A2S1TY A2S1VA A2S1HL A2S2TY A2S2VA A2S2HL ALHYST ALARM1 BLOCK DIAGAL

_______ _______ _______ _______ _______ _______ _______ _______ _______ _______

_______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______ _______

3 DIS ENAB ENAB 10 19200 30 FP_B PCT DIS

NONE 90 HIGH NONE 90 HIGH NONE 90 HIGH NONE 90 HIGH

0.1 NOL DIS DIS

DISPLY

DECML UNITS FREQ LWRDSP TCDIAG

_______ _______ _______ _______ _______

NONE F 60 ENAB ENAB

48 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

4 Operating the Limit Controller

4.1 Overview

Introduction

This section gives you all the information necessary to help you monitor 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.

4.1 Overview 49

Operating the Limit Controller

TOPIC See Page

4.2 Operator Interface 50

4.3 Entering A Security Code 50

4.4 Lockout Feature 51

4.5 Monitoring The Limit Controller 52

4.6 How to Operate Your Limit Controller 54

4.7 Alarm Setpoints 57

4.8 P.I.E. Tool Maintenance Screens 58

4.9 Configuring your Ethernet Connection 64

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 49

Operating the Limit Controller

4.2 Operator Interface

Introduction

Figure 5-1 is a view of the Operator Interface. A description of the displays and indicators is included.

Figure 4-1 Operator Interface

4.3 Entering a Security Code

Introduction

The level of keyboard 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.

Write the number on the Configuration Record Sheet in the configuration section so you will have a permanent record.

50 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Table 4-1 Procedure to Enter a Security Code

Step Operation Press Result

Operating the Limit Controller

1 Upper Display = SET UP

2 Upper Display = 0

Enter Set Up

Mode

Select any Set

Up Group

Security Code

Entry

SetupSetup

FunctionFunctionFunction

Lower Display = LOCK

Lower Display = SECUR

To enter a four digit number in the upper display

This will be your security code.

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 required. These levels are:

(0001 to 9999)

• NONE No Lockout. All groups Read/Write.

• CAL All groups Read/Write except Calibration

• CONF Configuration parameters are Read only. No writes permitted.

• +SP Only the Lockout group is available for Read/Write.

See above.

Key error

When a key is pressed and the prompt “Key Error” appears in the lower display, it will be for one of the following reasons:

Calibration Group is not available.

Setpoint value is Read Only.

Subsection 3.4- Lockout Parameters Set Up Group prompts to select one of the

• Parameter not available or locked out

• Not in setup mode, press

SET UP key first

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 51

Operating the Limit Controller

4.5 Monitoring Your Limit Controller

Annunciators

The following annunciator functions have been provided to help monitor the controller:

Table 4-2 Annunciators

Annunciator Indication

ALM 1 2 A visual indication of each alarm

Blinking 1 indicates alarm latched and needs to be acknowledged before extinguishing when the alarm condition ends

F or C

A visual indication of the temperature units

F—Degrees Fahrenheit

C—Degrees Celsius

Display Mode

The displays and indicators on the operator interface, as shown in Figure 4-1, let you see what is happening to your process and how the Limit Controller is responding.

The Limit Controller can be either a single line display device (except when in the SETUP mode or the

LOWER DISPLAY key is pressed or limit has been reached) or it can

be a dual line display device (upper display shows PV and lower display shows SP). This display can be one of two types:

Single Display Mode 1

The PV is displayed in the upper display and the lower display is blank.

Single Display Mode 2

The setpoint is displayed in the upper display and “SP” is displayed in the lower display.

Viewing the operating parameters

Press the LOWER DISPLAY key to scroll through the operating parameters: SP* Setpoint

PV Process Variable *

You can press to change the value of this parameter. or

Timing out from lower display

The normal variable display will automatically return in the upper display if the LOWER

DISPLAY

52 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

key is not pressed for 30 seconds.

Diagnostic Error Messages

The UDC2500 performs background tests to verify data and memory integrity. If there is a malfunction, an error message will be displayed. In the case of more than one simultaneous malfunction, the messages will be displayed sequentially on the lower display. If any of these error messages in

Troubleshooting

Prompt Description

for information to correct the failure.

Operating the Limit Controller

Table 4-3 occur, refer to Section 7 -

Table 4-3 Error Messages

EE FAIL

IN1FL

CNFERR

IN1RNG

PV LIM

FAILSF

TCWARN

TCFAIL

OUT2 FL

Unable to write to nonvolatile memory. Two consecutive failures of input 1 integration. Configuration Errors—Low limit greater than high limit for PV or SP Input 1 Out-of-Range

Out-of-range criteria: Linear range: ±10% out-of-range Characterized range: ±1% out-of-range

PV Out-of-Range PV = PV + PV bias

Failsafe — conditions for Failsafe are: … EEROM Test Failed … Scratch Pad RAM Test Failed … Configuration Test Failed Check the “Status” group.

Thermocouple sensor is starting to burnout. Thermocouple sensor is in imminent danger of burning out. Current Output 2 failure is less than 3.5 mA.

High and Low Limit Indication

When the high or low limit is exceeded, the lower display indicates the word “LIMIT” (blinking). The PV is indicated in the upper display. This will continue until the Out-ofLimit condition exists and you reset the latching relay using the

M-A RESET key or

through the Optional External Reset feature.

The Limit Relay cannot be reset while a Limit condition exists.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 53

Operating the Limit Controller

4.6 Operating Your Limit Controller

Operating Principles

The Limit Controller accepts signals from such sources as Thermocouples (T/Cs), Resistance Temperature Detectors (RTDs), and Radiamatics. The equivalent PV signal is compared with the Limit set point. If above (Hi Limit) or below (Lo Limit), a limit output relay is de-energized. When de-energized, the output relay locks out and remains in this state until the PV input signal drops below the high limit setpoint or rises above the low limit setpoint, and the controller is reset manually from the front of the controller or through an optional external switch.

Check the configuration

Make sure the Limit Controller has been configured to handle your process needs. Refer to

Section 3 - Configuration for prompts and parameters.

• Input Parameters

• Alarm Set Points and type

• Limit Control Type - high or low

• External Reset (Contact Input) - enable or disable

• Power-up Logic - Reset (relay on) or Normal (same as before power down)

• Lockout selection

Power Up Logic

Configurable power-up logic lets you select the latching output relay to require “RESET” or to provide normal operation at power-up. If power to the limit controller fails and power is reapplied, the controller goes through power up tests then starts in one of the following configurable conditions:

• If you configured RST at setup group “LIMIT”, the lower display will blink

“LIMIT” at power up. This will require reset via the

switch to obtain normal operation.

• If you configured NORM at setup group “LIMIT”, the display and limit controller

will function normally at power up, (that is, no reset of the latching relay is

required unless a limit has been exceeded). If the limit was latched when power

went down, the unit will be in limit at power-up. Refer to

Section 3 - Configuration, subsection 3.4 Limit Parameters Set Up Group under

SET UP prompt “LIMIT” and make your selection at FUNCTION prompt “POWRUP.”

M-A RESET key or external

54 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

How to set a limit setpoint

Step Operation Press Result

Operating the Limit Controller

1 Display

setpoint

2 Enter the Limit

Setpoint

3 Store the limit

setpoint

4 If the display

flashes "Limit"

Lower

Display

Press the "Lower Display" key till SP appears.

or Set the SP, using the Up & Down arrow keys, to the desired Limit

Setpoint

Lower

Display

M-A

Reset

Press the "Lower Display" to store the value.

Press the Auto-Man/ Reset key.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 55

Operating the Limit Controller

How to Reset the Latching Relay

The latching relay cannot be reset until the PV input signal drops below the high set point (High Limit) or rises above the low set point (Low Limit) value.

Press the M-A RESET key or make contact closure of an external switch if the External Reset option is present.

Using the Digital Input Option (External Reset)

The Contact Input option detects the state of external contacts. On contact closure, the controller will reset the latching relay if the controller has External Reset enabled. To allow External Reset (contact input) use the procedure in

Table 4-4.

Table 4-4 Using Contact Input Option

Step Operation Press Result

Select Options

Set-up Group

Access the

External Reset

Prompt

Change a value

SetupSetup

FunctionFunctionFunction

Until you see:

Upper Display = SET Lower Display = OPTIONS Until you see:

Upper Display = ENAB

DIS

Lower Display = DIGIN1 To select ENAB in the upper display

56 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

4.7 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

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– Configuration for details.

Alarm Setpoints Display

Table 4-5 Procedure for Displaying Alarm Setpoints

Step Operation Press Result

Table 2-3 in the Section 2 –

Operating the Limit Controller

Select Alarm

Set-up Group

Access the Alarm

Setpoint Values

Change a value

Return to Normal

Display

SetupSetup

FunctionFunctionFunction

Lower

Display

Until you see: Upper Display = SET

Lower Display = ALARMS

To successively display the alarm setpoints and their values. Their order of appearance is shown below.

Upper Display = (the alarm setpoint value) Range values are within the range of the selected parameters:

DE (Deviation) value = within Input 1 Span PV (Process variable) value = Within Input 1 range

To change any alarm setpoint value in the upper display

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 57

Operating the Limit Controller

4.8 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.I.E. 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.

Figure 4-2 Maintenance Data Menu

The Loop Data screen allows you to see the current status of the process loop. “OP1, 2 and 3” 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.

58 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Operating the Limit Controller

Figure 4-3 Loop Data Maintenance Screen

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 59

Operating the Limit 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

3.9 for other information about configuring Alarms.

Figure 4-4 Alarm Details Maintenance Screen

60 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

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.

Operating the Limit Controller

Figure 4-5 Digital Input Details Screen

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 61

Operating the Limit Controller

Status Data

Select “Status Data” from the “Maintenance Data” menu.

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. If the controller is equipped with the Real Time Clock Option, then pressing the “Diagnostics” button will show the time and dates that the problem occurred and when it was cleared.

Figure 4-6 Status Data Maintenance Screen

62 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Ethernet Status

Select “Ethernet Status” from the “Maintenance Data” menu.

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

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.

Operating the Limit Controller

7.5 for details.

Figure 4-7 Ethernet Status Maintenance Screen

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 63

Operating the Limit Controller

4.9 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 section show screen-shots from the PC version of the P.I.E. Tool 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

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 Communications Type as “Infrared” and your IR address to 3 as shown below.

can be used to configure Ethernet parameters. The figures in this

Screens. Pocket PC

Select “PC COMM Setup”, then, select “Infrared”.

Figure 4-8 IR Communications Address

64 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Operating the Limit Controller

Close the IR configuration window and then single click on the “Online Configuration” button.

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.I.E.

Tool

should start uploading the configuration information from the controller as shown below:

Figure 4-9 Configuration Upload in Progress

Once the upload is complete, click on the “Ethernet & Email” Group. Configure your Ethernet and Email parameters per Section

3.11.

Once you have changed the Ethernet settings and downloaded them to your controller, you will be able to communicate with it via Ethernet.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 65

Operating the Limit Controller

Configuring the Controller via Ethernet Communications

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 where 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 straightthrough 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.I.E. Tool

program and select “PC Comm Setup” and select Ethernet

as your “Communication Type” as shown in

Figure 4-10 Ethernet Communications Type Selection

Figure 4-10.

66 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Operating the Limit Controller

Now set your Ethernet address to 10.0.0.2 as shown in Figure 4-11.

Figure 4-11 Ethernet Communications Address

Close the Ethernet configuration window and then single click on the “Online Configuration” button.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 67

Operating the Limit Controller

Then, click on the “Start” button. The P.I.E. Tool® should start uploading the configuration information from the controller as shown in

Figure 4-12.

Figure 4-12 Configuration Upload in Progress

Once the upload is complete, click on the “Ethernet & Email” Group. Configure your Ethernet and Email parameters per Section

3.11.

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.I.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 if this is available on your PC.

68 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

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.

All input actuations in every UDC2500 controller are fully factory-calibrated and are

•

ready for configuration by the user.

• Field Calibration can improve the accuracy of the Controller if necessary for a

particular application.

Input Calibration

5 Input Calibration

WARNING—SHOCK HAZARD

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

What's in this section?

The following topics are covered in this section.

5.1 Overview 69

5.2 Minimum and Maximum Range Values 70

5.3 Preliminary Information 72

5.4 Input #1 Set Up Wiring 73

5.5 Input #1 Calibration Procedure 78

5.6 Restore Input Factory Calibration 79

5.6 if you want to restore factory calibration values.

TOPIC See Page

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 69

Input Calibration

Calibration Steps

Use the following steps when calibrating an input.

Step Action

Find the minimum and maximum range values for your PV input range from

Disconnect the field wiring and find out what equipment you will need to calibrate.

Wire the calibrating device to your controller according to the set up wiring instructions

for your particular input (Subsection Follow the calibration procedure given for Input #1 (Subsection

5.4).

5.5).

Table 5-1.

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. Use these values when calibrating your controller.

Table 5-1 Voltage, Milliamp and Resistance Equivalents for Input 1 Range Values

PV Input Range Range Values Sensor Type

°F °C 0 % 100 %

Thermocouples (per ITS-90)

B E

E (low)

J (med)

J (low)

K (med)

K (low)

NiMo-NiCo (NM90)

NM90 (low)

Nicrosil-Nisil (Nic)

Nic (low)

0 to 3300 –18 to 1816 –0.100 mV 13.769 mV –454 to 1832 –270 to 1000 –9.835 mV 76.373 mV –200 to 1100 –129 to 593 –6.472 mV 44.455 mV 0 to 1600 –18 to 871 –0.886 mV 50.060 mV

20 to 900 –7 to 482 26.400 mV 20 to 550 –7 to 288 –0.334 mV 15.650 mV

0 to 2400 –18 to 1316 –0.692 mV 52.952 mV

–20 to 1200 –29 to 649 –1.114 mV 26.978 mV

–20 to 750 –29 to 399 –1.114 mV 16.350 mV 32 to 2500 0 to 1371 0.000 mV 71.773 mV

32 to 1260 0 to 682 0.000 mV 31.825 mV 0 to 2372 –18 to 1300 –0.461 mV 47.513 mV 0 to 1472 –18 to 800 -0.461 mV 28.455 mV 0 to 3100 –18 to 1704 –0.090 mV 20.281 mV

–0.334 mV

70 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Input Calibration

PV Input Range Range Values Sensor Type

°F °C 0 % 100 % S T

T (low)

W5W26

W5W26 (low)

RP20-RP40

Thermocouple

Differential *

Radiamatic

Type RH Type RI **

RTD Alpha = 0.00385 per IEC-60751 (1995)

100 ohms

100 ohms (low)

200 ohms 500 ohms

Linear

0 to 3100 –18 to 1704 –0.092 mV 17.998 mV

-300 to 700 –184 to 371 –5.341 mV 19.097 mV

-200 to 500 –129 to 260 –4.149 mV 12.574 mV 0 to 4200 –18 to 2315 –0.234 mV 37.075 mV 0 to 2240 –18 to 1227 –0.234 mV 22.283 mV 32 to 3216 0 to 1880 0.000 mV 4.933 mV

–50 to 150 –46 to 66 –1.54 mV 4.62 mV

0 to 3400 –18 to 1871 0.00 mV 0 to 9999 0 to 9999

–300 to 1200 –300 to 300 –300 to 1200 –300 to 1200

–184 to 649 –184 to 149 –184 to 649 –184 to 649

126.012 ohms

57.12 mV

0.00 mV

25.202 ohms

50.404 ohms

60.08 mV

329.289 ohms

156.910 ohms

658.578 ohms

1646.445 ohms

Milliamps

Millivolts

Volts

4 to 20 mA 0 to 20 mA

0 to 10 mV 0 to 50 mV 0 to 100 mV

1 to 5 Volts 0 to 5 Volts 0 to 10 Volts

4.00 mA

0.00 mA

0.00 mV

1.00 Volts

0.00 Volts

20.00 mA

10.00 mV

50.00 mV

100.00 mV

5.00 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. See 5-7

for procedure.

Table

** The range values for Radiamatic Type RI are customer configurable.

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Input Calibration

5.3 Preliminary Information

Disconnect the Field Wiring

Tag and disconnect any field wiring connected to the input terminals on the rear of the controller.

Equipment Needed

Table 5-2 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.

Type of Input Equipment Needed

Thermocouple Inputs (Ice Bath)

Input 1

Connections

R +

Input 1

25 R 26 + 27 –

Figure 5-1 Input 1 Wiring Terminals

Table 5-2 Equipment Needed

•

A calibrating device with at least ± 0.02 % accuracy for use as a signal source such as a millivolt source.

Thermocouple extension wire that corresponds with the type of

• thermocouple that will be used with the controller input.

Two insulated copper leads for connecting the thermocouple

• extension wire from the ice baths to the mV source.

Two containers of crushed ice.

•

Thermocouple Inputs (T/C Source)

RTD (Resistance Thermometer Device)

Milliampere, Millivolt, Volts, and Radiamatic

72 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

•

A calibrating device with at least ± 0.02 % accuracy for use as a signal source such as a millivolt source.

Thermocouple extension wire that corresponds with the type of

• thermocouple that will be used with controller input.

A decade box, with at least ± 0.02 % accuracy, capable of providing

• stepped resistance values over a minimum range of 0 to 1400 ohms with a resolution of 0.1 ohm.

Three insulated copper leads of equal length for connecting the

• decade box to the controller.

A calibrating device with at least ± 0.02 % accuracy for use as a

• signal source.

Two insulated copper leads for connecting the calibrator to the

• controller.

Place current source at zero before switching ON.

• Do not switch current sources OFF/ON while connected to the

• 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 5-3.

Table 5-3 Set Up Wiring Procedure for Thermocouple Inputs

Using an Ice Bath

Step Action

Connect the copper leads to the calibrator.

Connect a length of thermocouple extension wire to the end of each copper lead and

insert the junction points into the ice bath. Connect the thermocouple extension wires to the terminals for Input #1.

Figure 5-2.

See

Input Calibration

Millivolt Source

Copper Leads

Ice Bath

Thermocouple Extension Wire

26 27

Figure 5-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath

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Input Calibration

Thermocouple Inputs Using a Thermocouple Source

Refer to Figure 5-3 and wire the controller according to the procedure given in Table 5-4

Table 5-4 Set Up Wiring Procedure for Thermocouple Inputs using

Thermocouple Source

Step Action

Connect the thermocouple extension wires to the terminals for Input #1 as shown in

Figure 5-3.

Thermocouple

Source

26 27

RTD Inputs

Refer to Figure 5-4 and wire the controller according to the procedure given in Table 5-5.

Step Action

Thermocouple Extension Wire

Figure 5-3 Wiring Connections for Thermocouple Inputs Using

Thermocouple Source

Table 5-5 Set Up Wiring Procedure for RTD Inputs

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

25R 26+

27-

Figure 5-4 Wiring Connections for RTD (Resistance Thermometer Device)

74 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Radiamatic, Millivolts, Volts or Thermocouple Differential Inputs

Refer to Figure 5-5 and wire the controller according to the procedure given in Table 5-6.

Table 5-6 Wiring Connections for Radiamatic, Thermocouple Differential,

Millivolts or Volts (Except 0 to 10 Volts)

Step Action

Connect the copper leads from the calibrator to the Input #1 terminals as shown in

Figure 5-5. Place current/voltage source at zero before switching on.

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 Configuration3.6 – Set Up prompt INPUT1, function prompt EMISS.

Millivolt or Volt Source

26+ 27-

Input Calibration

Figure 5-5 Wiring Connections for Radiamatic, Millivolts, Volts or

Thermocouple Differential (Except 0 to 10 Volts)

Table 5-7 Procedure to determine calibration voltages for Thermocouple

Differential input types other than the Factory Setting

Step Action

Obtain a copy of the ITS-90 Standard for the Thermocouple Type you will be using.

Find the thermoelectric voltage for the desired operating temperature.

Find the thermoelectric voltages for the temperatures –50°F and +150°F away from the desired operating temperature.

The zero calibration voltage will be thermoelectric voltage for the –50°F temperature minus the thermoelectric voltage for the desired operating temperature. This will be a negative voltage.

The span calibration voltage will be thermoelectric voltage for the +150°F temperature minus the thermoelectric voltage for the desired operating temperature. This will be a positive voltage.

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 75

Input Calibration

For example: Determine the calibration voltage values for a pair of J-type thermocouples at an operating temperature of 450

• The ITS-90 standard for the J thermocouple shows that the thermoelectric

• The –50°F point would be 400°F. The ITS-90 standard shows that the

• The +150°F point would be 600°F. The ITS-90 standard shows that the

• The zero calibration voltage is thus 11.025 minus 12.568 millivolts or –1.543

• The span calibration voltage is thus 17.188 minus 12.568 millivolts or +4.62

• Use –1.54 millivolts for the Zero calibration value and +4.62 millivolts for the

°F (this is equivalent to the Factory setting).

voltage for 450

thermoelectric voltage for 400

thermoelectric voltage for 600

°F is 12.568 millivolts.

°F is 11.025 millivolts.

°F is 17.188 millivolts.

millivolts (this can be rounded off to –1.54 millivolts without significant loss of accuracy).

millivolts.

Span calibration value.

0 to 10 Volts

Refer to Figure 5-6 and wire the controller according to the procedure given in Table 5-8.

Step Action

Table 5-8 Set Up Wiring Procedure for 0 to 10 Volts

Connect the copper leads from the calibrator to the Input #1 terminals as shown in Figure 5-6.

Place voltage source at zero before switching on. Do not switch voltage source ON/OFF while connected to the instrument.

Volt

Source

100K pair

1 2

26+ 27-

Figure 5-6 Wiring Connections for 0 to 10 Volts

76 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Milliamperes

Refer to Figure 5-5 and wire the controller according to the procedure given in Table 5-6.

Step Action

Figure 5-7 Wiring Connections for 0 to 20 mA or 4 to 20 mA Inputs

Input Calibration

Table 5-9 Set Up Wiring Procedure for Milliampere Inputs

Connect the copper leads from the calibrator to the Input #1 terminals as shown in Figure 5-7.

Place current source at zero before switching on. Do not switch current source ON/OFF while connected to the instrument.

Milliampere

Source

250 ohms

26+ 27-

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Input Calibration

5.5 Input 1 Calibration Procedure

Preliminary Steps

Apply power and allow the controller to warm up for 30 minutes before you calibrate. •

•

Please read Subsection 5.4 – Input 1 Set Up Wiring before beginning the procedure.

•

Make sure you have LOCK set to NONE. See Subsection 3.4.

•

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

Step Operation Press Result

1 Upper Display = CAL

Enter Calibration Mode

Calibrate 0 %

SetupSetup

until you see

FunctionFunctionFunction

Lower Display = INPUT1

You will see:

Upper Display = DIS Lower Display = CALIN1

The calibration sequence is enabled and you will see:

Upper Display = BEGN Lower Display = CALIN1

At the completion of the sequence, the selection automatically reverts to disable.

You will see:

Upper Display = APLY Lower Display = IN1ZRO

•

Adjust your calibration device to an output signal equal to the 0 % range value for your particular input sensor.

Table 5-1 for Voltage, Degrees, or Resistance

See equivalents for 0 % range values.

•

Wait 15 seconds, then go to the next step.

78 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Calibrate 100 %

FunctionFunctionFunction

You will see:

Upper Display = APLY

Step Operation Press Result

Lower Display = IN1SPN

•

Adjust your calibration device to an output signal equal to the 100 % range value for your particular input sensor. See

Table 5-1 for Voltage, Degrees, or

Resistance equivalents for 100 % range values.

•

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

Input Calibration

Check the Cold Junction Temperature

FunctionFunctionFunction

The calculations for zero and span are now stored and you will see:

Upper Display = The cold junction temperature at the rear

terminals

Lower Display = CJTEMP

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

or keys.

WARNING: The accuracy of the controller is directly affected by the accuracy of this value. It is recommended that this value not be changed under normal circumstances.

Exit the Calibration Mode

FunctionFunctionFunction

The controller stores the calibration constants and exits the calibration mode.

then

Lower

Display

5.6 Restore Input Factory Calibration

Introduction

The factory calibration constants for all the input actuation types that can be used with the controller 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 5-11 Restore Input Factory Calibration for procedure.

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Input Calibration

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 the

Section - Configuration for specific instructions to set the lockout. 3

Table 5-11 Restore Input Factory Calibration

Step Operation Press Result

Set LOCKOUT to NONE

Enter INPUT 1 Setup Group

Scroll through Functions

SetupSetup

FunctionFunctionFunction

SetupSetup

FunctionFunctionFunction

until you see:

Upper Display Lower Display = LOCK

= SET UP

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

Lower Display = LOCK

Until NONE is in the upper display until you see:

Upper Display Lower Display = INPUT 1

= SET UP

until you see:

Upper Display Lower Display = IN1TYP

= the current selection

to change the current selection to another selection

until the lower display rolls through the rest of the functions and returns to:

Upper Display = the new selection Lower Display = INxTYP

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

Return to Normal Operation

Lower

Display

to return to Normal operating mode. The factory calibration will be restored.

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Input Calibration

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 81

6.1 Overview

Introduction

This section describes the field calibration procedures for the Auxiliary Output.

What's in this section?

The following topics are covered in this section.

6.1 Overview 83

6.2 Auxiliary Output Calibration 83

6.3 Restore Output Factory Calibration 85

Output Calibration

6 Output Calibration

TOPIC See Page

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.

6.2 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 current output range of from 0 mA to 20 mA and can be 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.

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 6-1 and wire the controller according to the procedure given in Table 6-1.

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Output Calibration

Step Action

2 Set LOCK in the Tuning Set Up group to NONE.

Table 6-1 Set Up Wiring Procedure for Auxiliary Output

Apply power and allow the controller to warm up 30 minutes before you calibrate.

Tag and disconnect the field wiring, at the rear of the controller, from terminals 12 (+) and 13 (–). See

Connect a milliammeter across these terminals.

Figure 6-1.

Milliammeter

xxxx

Figure 6-1 Wiring Connections for Calibrating Auxiliary Output

84 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Procedure

The procedure for calibrating the auxiliary output is listed in Table 6-2. The numeric codes are also listed.

Make sure “LOCK” in the Lock Set Up group is set to “NONE” (see Subsection 3.4).

Table 6-2 Auxiliary Output Calibration Procedure

Step Operation Press Result

Output Calibration

1 Upper Display = CAL

Enter Calibration Mode

SetupSetup

Lower Display = AUXOUT

until you see

Calibrate 0 %

FunctionFunctionFunction

You will see:

Upper Display = A Value Lower Display = ZROVAL

until the desired 0 % output is read on the milliammeter, use the values shown below depending on the action of your controller.

Calibrate 100 %

FunctionFunctionFunction

To store the 0 % value you will see:

Upper Display = A Value Lower Display = SPNVAL

until the desired 100 % output is read on the milliammeter.

The controller stores the span value.

To exit the calibration mode.

Exit the Calibration Mode

FunctionFunctionFunction

Lower

Display

6.3 Restore Output Factory Calibration

Introduction

The factory calibration constants for the Auxiliary Outputs are stored in its non-volatile memory. Thus, you can quickly restore the “Factory Calibration” for those outputs by simply changing the ARANGE to the other setting and then changing it back to the original type.

Refer to Table 6-3 Restore Factory Calibration for procedure

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Output Calibration

ATTENTION

A restored factory calibration overwrites any previous field calibration done for the output. Protect your field calibration from accidental overwrites by configuring the appropriate LOCKOUT selection after calibration.

Section - Configuration for specific instructions to set the lockout. 3

See

Table 6-3 Restore Factory Calibration

Step Operation Press Result

Set LOCKOUT to NONE

Enter OUTPUT or OPTIONS Setup Group

Scroll through Functions

SetupSetup

FunctionFunctionFunction

SetupSetup

FunctionFunctionFunction

until you see:

Upper Display Lower Display = TUNING

= SET

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

Until NONE is in the upper display until you see:

Upper Display Lower Display = OPTION (for the Auxiliary Output)

= SET

until you see:

Upper Display Lower Display = ARANGE (for the Auxiliary Output)

= the current selection

to change the range configuration to the other selection

until the lower display rolls through the rest of the functions and returns to:

Upper Display = the new selection Lower Display = ARANGE (for the Auxiliary Output)

to change the range selection in the upper display back to the proper selection. You will see:

Upper Display = Original range selection Lower Display = ARANGE (for the Auxiliary Output)

Return to Normal Operation

Lower

Display

to return to Normal operating mode. The factory calibration will be restored.

86 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

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:

• installation related problems

• application related problems

• hardware and software related problems

and use the information presented in this section to solve them.

What's in this section?

Troubleshooting/Service

7 Troubleshooting/Service

The following topics are covered in this section.

TOPIC See Page

7.1 Overview 87

7.2 Troubleshooting Aids

• Overall Error Messages

• Controller Failure Symptoms

• Customer Support

• Determining the Software Version Number

7.3 Power-up Tests 90

7.4 Status Tests 90

7.5 Background Tests 91

7.6 Controller Failure Symptoms 93

7.7 Troubleshooting Procedures

• Power Failure

• Alarm Relay Output Failure

• Keyboard Failure

7.8 Restore Factory Configuration 100

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

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 87

Troubleshooting/Service

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 troubleshooting 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:

• At power-up. See Subsection 7.3.

• When the Status Tests are requested. See Subsection 7.4.

• 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 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.

Table 7-4 to determine what is wrong and the

88 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

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

Step Operation Press Result

Select

STATUS Set Up Group

Read the software

version

SetupSetup

FunctionFunctionFunction

Upper Display = READ Lower Display = STATUS

You will see:

Upper Display = Software version number

26xx

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.

Troubleshooting/Service

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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.

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 Results

Step Operation Press Result

Select

STATUS Set Up Group

Read the test

results

SetupSetup

FunctionFunctionFunction

Upper Display = READ Lower Display = STATUS

You will see:

Upper Display = NO or YES YES indicates a failure Lower Display = FAILSAFE

Upper Display = PASS or FAIL Lower Display = TEST

90 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

Honeywell UDC2500 Operating Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

About This Document

Abstract

Symbol Definitions

Contents

Figures

1.1 Overview

1 Introduction

1.1.1 Function of keys

1.2 Process Instrument Explorer Software

1.3 CE Conformity (Europe)

2.1 Overview

2 Installation

2.2 Condensed Specifications

2.3 Model Number Interpretation

2.4 Limit and Alarm Relay Contact Information

2.5 Mounting

2.6 Wiring

2.6.1 Electrical Considerations Line voltage wiring

2.7 Wiring Diagrams

2.8 Limit Control Application Diagram

3.1 Overview

3 Configuration

3.2 Configuration Prompt Hierarchy

3.3 Configuration Procedure

3.4 Lock Set Up Group

3.5 Limit Set Up Group

3.6 Input 1 Set Up Group

3.7 Options Set Up Group

3.8 Communications Set Up Group

3.9 Alarms Set Up Group

3.10 Display Set Up Group

3.11 P.I.E. Tool Ethernet and Email Configuration Screens

3.12 Configuration Record Sheet

4 Operating the Limit Controller

4.1 Overview

4.2 Operator Interface

4.3 Entering a Security Code

4.4 Lockout Feature

4.5 Monitoring Your Limit Controller

4.6 Operating Your Limit Controller

4.7 Alarm Setpoints

4.8 P.I.E. Tool Maintenance Screens

4.9 Configuring your Ethernet Connection

5.1 Overview

5 Input Calibration

5.2 Minimum and Maximum Range Values

5.3 Preliminary Information

5.4 Input 1 Set Up Wiring

5.5 Input 1 Calibration Procedure

5.6 Restore Input Factory Calibration

6.1 Overview

6 Output Calibration

6.2 Auxiliary Output Calibration

6.3 Restore Output Factory Calibration

7.1 Overview

7 Troubleshooting/Service

7.2 Troubleshooting Aids

7.3 Power-up Tests

7.4 Status Tests