Honeywell UDC2500 Operating Manual

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

Contents

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

Lower

Lower

Display

Display

Display

Reset

Reset

Reset

Select

Select

Select

M-A

M-A

M-A

SP

SP

SP

Run

Run

Run

Hold

Hold

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

PC

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

21

21

22

22

23

24

24

25

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

ϕ

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

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

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 _ _ _

10

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

Tags

Future Options

CE, UL and CSA (Standard)
CE, UL, CSA and FM
None
Stainless Steel Customer ID Tag - 3 lines w/22 characters/line
None
None
None

TABLE V - Product Manuals

Product Information on CD - All Languages 0 _
English Manual (51-52-25-127) E _

Manuals

Certificate

French Manual (51-52-25-127-FR) F _
German Manual (51-52-25-127-DE) G _
Italian Manual (51-52-25-127-IT) I _
Spanish Manual (51-52-25-127-SP)
None
Certificate of Conformance (F3391)

continued

E _
A _
T _

_ 0
_ B
_ E
_ A
_ T

0 _ _ _
1 _ _ _
2 _ _ _

_ L _ _
_ _ 0 _

_ _ _ 0

_ _ _ R

1 _ _
2 _ _
3 _ _
_ 00

Selection

0 _ _ _ _
1 _ _ _ _
_ 0 _ _ _
_ T _ _ _
_ _ 0 _ _
_ _ _ 0 _
_ _ _ _ 0

Selection

S _
_ 0
_ C

Availability

DC 2500 2501

Availability

DC2500 2501

Availability

DC 2500 2501

bb

Availability

DC2500 2501

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 11

Installation

Limit Controller Restrictions/Comments:

1. FM approved units with communications are limited to read only.

2. FM approved units are restricted to TC and RTD type inputs.

3. UL listed for regulatory use only.

b
c

II

Input 2 Not Available with Limit Model

_ L _

Figure 2-1 Model Number Interpretation

12 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07

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

On

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

On

Indicators

Off

On

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

On

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

1

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

2

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

3

• 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

4

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).

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

2

) 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

1

2 Analog signal wire, such as:

3

• 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

A

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

18

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

A

1

3

C/DC

Line

Voltage

1

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

2

Ground

Neutral

Hot

10

L1

11

L2/N

4
5
6

7
8
9

12
13

14
15
16
17

18

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

2

) copper
conductor is recommended. Before powering the controller, see “Prelimnary Checks”
in this section of the Product Manual.

2

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.

3

CAUTION

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

damage the instrument and is a fire and smoke hazard.

xxxx

Figure 2-5 Mains Power Supply

3/07 UDC2500 Universal Digital Limit ControllerProduct Manual 19

Installation

Ω

Input #1

Millivolt or Volts

–

Xmitter

+

RTD

Power

Supply

250

except 0-10 Volts

25

2627+

R

–

source

mV or

Volt

source

+
–

Thermocouple Differential

Use Thermocouple

25

1

–+

26

27

extension wire only

R
+
–

+
–

2

–
+

Thermocouple

Use Thermocouple
extension wire only

3

25

R

26

+
–

27

0-10 Volts Milliamps

25
26

27

R
+

–

+

1

100K

0–10

Volt

source

1

2

3

2

1

100K

3

–

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.

25

R
+

26

27

–

25

R

26

+
–

27

xxxx

Figure 2-6 Input 1 Connections

20 UDC2500 Universal Digital Limit ControllerProduct Manual 3/07