Honeywell UDC3200 User Manual

UDC3200

Universal Digital Controller

Operator Manual

51-52-25-143 April 2008

Honeywell Process Solutions

Notices and Trademarks

Copyright 2008 by Honeywell

April 2008

WARRANTY/REMEDY

Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of coverage, Honeywell will repair or replace without charge those items it finds defective. The foregoing is Buyer's sole remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and fitness for a particular purpose. Specifications may change without notice. The information we supply is believed to be accurate and reliable as of this printing. However, we assume no responsibility for its use.

While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the customer to determine the suitability of the product in the application.

Contacts

World Wide Web

The following lists Honeywell’s World Wide Web sites that will be of interest to our customers.

Honeywell Organization	WWW Address (URL)
Corporate	http://www.honeywell.com
Honeywell Process Solutions	http://hpswebhoneywell.com

Telephone

Contact us by telephone at the numbers listed below.

	Organization	Phone Number
United States and Canada	Honeywell	1-800-423-9883	Tech. Support
		1-800-525-7439	Service

Web

http://content.honeywell.com/ipc/faq/

Honeywell Process Solutions

512 Virginia Drive

Fort Washington, PA 19034

UDC3200 is a U.S. registered trademark of Honeywell

Other brand or product names are trademarks of their respective owners.

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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.

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			Contents
1	INTRODUCTION ...................................................................................................			1
1.1		Operator Interface ...........................................................................................................................		1
1.2		Function of Displays and Keys .......................................................................................................		1
1.3		CE Conformity (Europe).................................................................................................................		2
2	INSTALLATION.....................................................................................................			5
2.1		Pre-installation Information ............................................................................................................		5
2.2		Model Number Interpretation .........................................................................................................		5
2.3		Control and Alarm Relay Contact Information...............................................................................		6
2.4		Mounting.........................................................................................................................................		7
2.5		Wiring .............................................................................................................................................		9
	2.5.1		Electrical Considerations .....................................................................................................	9
2.6		Wiring Diagrams...........................................................................................................................		10
3	CONFIGURATION...............................................................................................			24
3.1		Configuration Prompt Hierarchy ..................................................................................................		24
3.2		Configuration Procedure...............................................................................................................		25
3.3		Tuning Set Up Group....................................................................................................................		26
3.4		SP Ramp Set Up Group ................................................................................................................		29
3.5		Accutune Set Up Group ................................................................................................................		32
3.6		Algorithm Set Up Group...............................................................................................................		33
3.7		Output Set Up Group ....................................................................................................................		39
3.8		Input 1 Set Up Group....................................................................................................................		42
3.9		Input 2 Set Up Group....................................................................................................................		45
3.10 Control Set Up Group ...............................................................................................................				48
3.11		Options Group ...........................................................................................................................		53
3.12		Communications Group ............................................................................................................		57
3.13 Alarms Set Up Group ................................................................................................................				59
3.14 Display Set Up Group ...............................................................................................................				63
4	MONITORING AND OPERATING THE CONTROLLER.....................................			65
4.1		Operator Interface .........................................................................................................................		65
4.2		Entering a Security Code ..............................................................................................................		65
4.3		Individual key lockout ..................................................................................................................		66
4.4		Monitoring Your Controller..........................................................................................................		67
	4.4.1		Annunciators ......................................................................................................................	67
	4.4.2 Viewing the operating parameters......................................................................................			68
	4.4.3		Diagnostic Messages..........................................................................................................	69
4.5		Accutune III ..................................................................................................................................		71
	4.5.1 Tune for Simplex Outputs..................................................................................................			72
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	4.5.2 Tune for Duplex (Heat/Cool).............................................................................................	73
	4.5.3 Using AUTOMATIC TUNE at start-up for Duplex (Heat/Cool) ......................................	74
	4.5.4 Using BLENDED TUNE at start-up for Duplex (Heat/Cool) ...........................................	75
	4.5.5 Using MANUAL TUNE at start-up for Duplex (Heat/Cool).............................................	75
	4.5.6 Error Codes ........................................................................................................................	77
4.6	Fuzzy Overshoot Suppression.......................................................................................................	78
5	TROUBLESHOOTING/SERVICE........................................................................	79
5.1	Background Tests..........................................................................................................................	79
5.2	Controller Failure Symptoms........................................................................................................	81
6	SALES AND SERVICE........................................................................................	82

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1 Introduction

1.1 Operator Interface

Figure 1-1 UDC3200 Operator Interface

1.2 Function of Displays and Keys

Table 1-1 Function of Displays and Keys

Display Indicators

3200	Upper display with 4 large digits shows
	Process Variable value (normal operation)
	and special annunciator features. During
	Configuration, the upper display provides
	guidance for the operator through prompts (7
	– characters)

				During normal operation, the lower display
SP 3200
				shows key-selected operating parameters
				such as Output, Setpoints, Inputs, Deviation,
				active Tuning Parameter Set, Timer Status, or
				minutes remaining in a setpoint ramp (4
				digits). During configuration, the lower display
				provides guidance for the operator through
				prompts (8-characters).
				Indicates Alarm 1 and/or Alarm 2 conditions
	ALM
				exist.
				Indicates Digital Input 1 and/or 2 on.
		DI

OUT Indicates Control Relay 1 and/or 2 on.

	F
Or			Indicates either degrees
			Fahrenheit or Centigrade.
	C

MAN
Or		Indicates either Manual or Auto
A		mode.
		Indicates Local Setpoint #1.
SP
		Also, a bar is lighted when the
		setpoint being used is shown on
		the lower display.

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Keys and Functions

	Function	Selects functions within each
		configuration group.

Scrolls through the configuration Setup groups.

Lower	Returns Controller to normal display
Display	from Set Up mode. Toggles various
	operating parameters for display.

Increases setpoint or output value. Increases the configuration values or changes functions in Configuration mode groups.

Infrared transceiver

Man

Auto

SP

Select

Run

Hold

Selects Manual or Auto mode.

Hold key down to cycle through configured setpoints.

Enables Run/Hold of the SP Ramp or Program plus Timer start.

Decreases setpoint or output value. Decreases the configuration values or changes functions in Configuration mode groups.

NEMA4X and IP66 screw attachment (each corner)

1.3 CE Conformity (Europe)

This product is in conformity with the protection requirements of the following European Council Directives: 73/23/EEC, the Low Voltage Directive, and 89/336/EEC, the EMC Directive. Conformity of this product with any other “CE Mark” Directive(s) shall not be assumed.

Product Classification: Class I: Permanently connected, panel-mounted Industrial Control Equipment with protective earthing (grounding) (EN61010-1).

Enclosure Rating: This controller must be panel-mounted with the rear terminals enclosed within the panel. The front panel of the controller is rated at NEMA4X and IP66 when properly installed.

Installation Category (Overvoltage Category): Category II (EN61010-1)

Pollution Degree: Pollution Degree 2: Normally non-conductive pollution with occasional conductivity caused by condensation. (Ref. IEC 664-1)

EMC Classification: Group 1, Class A, ISM Equipment (EN61326, emissions), Industrial Equipment (EN61326, immunity)

Method of EMC Assessment: Technical File (TF) Declaration of Conformity: 51453663

Deviation from the installation conditions specified in this manual, and the special conditions for CE conformity in Subsection 2, may invalidate this product’s conformity with the Low Voltage and EMC Directives.

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ATTENTION

The emission limits of EN61326 are designed to provide reasonable protection against harmful interference when this equipment is operated in an industrial environment. Operation of this equipment in a residential area may cause harmful interference. This equipment generates, uses, and can radiate radio frequency energy and may cause interference to radio and television reception when the equipment is used closer than 30 meters (98 feet) to the antenna(e). In special cases, when highly susceptible apparatus is used in close proximity, the user may have to employ additional mitigating measures to further reduce the electromagnetic emissions of this equipment.

WARNING

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

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2Installation

2.1Pre-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.

2.2Model Number Interpretation

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.

Instructions

Select the desired key number. The arrow to the right marks the selection available.

Make the desired selections from Tables I through VI using the column below the

proper arrow.

A dot (

) denotes availability.

Key Number

I

II

III

IV

V

VI

_ _ _ _ _ _

-

_ _

-

_ _ _ _

-

_ _ _

-

_ _ _ _ _

-

_ _

_

KEY NUMBER - UDC3200 Single Loop Controller

Description

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

TABLE I - Specify Control Output and/or Alarms

Selection Availability

DC3200

DC3201

	Current Output (4 to 20ma, 0 to 20 ma)
	Electro Mechanical Relay (5 Amp Form C)
Output #1	Solid State Relay (1 Amp)
	Open Collector transistor output
	Dual 2 Amp Relays (Both are Form A) (Heat/Cool Applications)
	No Additional Outputs or Alarms
Output #2 and Alarm	One Alarm Relay Only
#1 or Alarms 1 and 2	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)

C _ E _ A _ T _ R _

_ 0 _ B _ E _ A _ T

TABLE II - Communications and Software Selections

		None
	Communications	Auxiliary Output/Digital Inputs (1 Aux and 1 DI or 2 DI)
		RS-485 Modbus Plus Auxiliary Output/Digital Inputs
		10 Base-T Ethernet (Modbus RTU) Plus Auxiliary Output/Digital Inputs
		Standard Functions, Includes Accutune
	Software Selections	Math Option
		Set Point Programming (1 Program, 12 Segments)
		Set Point Programming Plus Math
	Reserved	No Selection
	Infrared interface	Infrared Interface Included (Can be used with a Pocket PC)

0 _ _ _

1 _ _ _

2 _ _ _

3 _ _ _

_ 0 _ _ _ A _ _ _ B _ _ _ C _ _

_ _ 0 _

_ _ _ R

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

		TC, RTD, mV, 0-5V, 1-5V
	Input 1	TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA
		TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA, 0-10V
		Carbon, Oxygen or Dewpoint (Requires Input 2)
		None
	Input 2	TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA
		TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA, 0-10V
		Slidewire Input (Requires two Relay Outputs)

1 _ _

2 _ _

3 _ _

1 6 0

_ 00 _ 10 _ 20 _ 40

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TABLE IV - Options

	Approvals	CE (Standard)
		CE, UL and CSA
	Tags	None
		Linen Customer ID Tag - 3 lines w/22 characters/line
		Stainless Steel Customer ID Tag - 3 lines w/22 characters/line
	Future Options	None
		None
		None

TABLE V - Product Manuals

		Product Information on CD - All Languages
		English Manual
	Manuals	French Manual
		German Manual
		Italian Manual
		Spanish Manual
	Certificate	None
		Certificate of Conformance (F3391)
	TABLE VI

No Selection

None

0 _ _ _ _

1 _ _ _ _

_ 0 _ _ _

_ T _ _ _

_ S _ _ _

_ _ 0 _ _

_ _ _ 0 _

_ _ _ _ 0

0 _

E_

F_

G_

I _

S _

_ 0 _ C

0 _

Figure 2-1 Model Number Interpretation

2.3 Control and Alarm Relay Contact Information

Control Relays

ATTENTION

Control relays operate in the standard control mode (that is, energized when output state is on).

Table 2-1 Control Relay Contact Information

	Unit Power	Control Relay		Control Relay		Output #1 or #2
		Wiring		Contact		Indicator Status
	Off	N.O.		Open		Off
		N.C.		Closed
	On	N.O.		Open		Off
				Closed		On
		N.C.		Closed		Off
				Open		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.

Table 2-2 Alarm Relay Contact Information

	Unit			Alarm Relay		Variable NOT in Alarm State			Variable in Alarm State
	Power			Wiring		Relay	Indicators		Relay	Indicators
						Contact			Contact
	Off			N.O.		Open	Off		Open	Off
				N.C.		Closed			Closed
	On			N.O.		Closed	Off		Open	On
				N.C.		Open			Closed

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2.4 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 Figure 2-2.

•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

	Max. panel thickness
mm	19,1
		9,0
	.75
inches		0,35

92,0 + 0,8 - 0,00

3,62 + 0,03 -0,00

90,6 108,6 3,57 4,28

Panel

Cutout

	92,0	+ 0,8
								113,1
		- 0,00
			17,9					4,45
	3,62	+ 0,03
			0,70
		-0,00

Figure 2-2 Mounting Dimensions (not to scale)

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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.

Mounting clips

Attach screws and washers here for water protection

				Figure 2-3 Mounting Methods
Mounting Procedure
				Table 2-3 Mounting Procedure
	Step			Action

1Mark and cut out the controller hole in the panel according to the dimension information in Figure 2-2.

2Orient the case properly and slide it through the panel hole from the front.

3Remove 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.

4For water-protected installation, install four screws with washers into the four recessed areas in the corners of the front bezel (Figure 2-3). Push the point of the screw through the center piercing the elastomeric material and then tighten screws to 5 lb-in (56 N•cm).

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2.5 Wiring

2.5.1 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 circuit-breaker shall be located in close proximity to the controller, within easy reach of the OPERATOR. The switch or circuit-breaker shall be marked as the disconnecting device for the controller.

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.

When applying power to multiple instruments, make certain that sufficient current is supplied. Otherwise, the instruments may not start up normally due to the voltage drop caused by the in-rush current.

Controller Grounding

PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is installed shall be in accordance with National and Local electrical codes. To minimize electrical noise and transients that may adversely affect the system, supplementary bonding of the controller enclosure to a local ground, using a No. 12 (4 mm2) 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, Table 2-4.

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:

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•Separate External Wiring—Separate connecting wires into bundles

(See Permissible Wiring Bundling - Table 2-4) and route the individual bundles through separate conduit metal trays.

Use Suppression Devices—For additional noise protection, you may want to add suppression devices at the external source. Appropriate suppression devices are commercially available.

ATTENTION

For additional noise information, refer to document number 51-52-05-01, How to Apply Digital Instrumentation in Severe Electrical Noise Environments.

Permissible Wiring Bundling

Table 2-4 Permissible Wiring Bundling

Bundle No.

Wire Functions

1• Line power wiring

•Earth ground wiring

•Line voltage control relay output wiring

•Line voltage alarm wiring

2Analog signal wire, such as:

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

•4-20 mA output signal wiring

Digital input signals

3• Low voltage alarm relay output wiring

•Low voltage wiring to solid state type control circuits

•Low voltage wiring to open collector type control circuits

2.6Wiring Diagrams

Universal Output Functionality and Restrictions

Instruments with multiple outputs can be configured to perform a variety of output types and alarms. For example, an instrument with a current output and two relays can be configured to perform any of the following:

1)Current Simplex with two alarm relays;

2)Current Duplex 100% with two alarm relays;

3)Time Simplex with one alarm relay;

4)Time Duplex with no alarm relays; or

5)Three Position Step Control with no alarm relays.

These selections may all be made via the keyboard and by wiring to the appropriate output terminals; there are no internal jumpers or switches to change. This flexibility allows a customer to stock a single instrument which is able to handle a variety of applications.

Table 2-5 shows what control types and alarms are available based upon the installed outputs. In this table, when Duplex Control and Reverse Action are configured, “Output 1” is HEAT while “Output 2” is COOL. When Three Position Step Control is configured, “Output 1” is OPEN while “Output 2” is CLOSE. The Output 1/2 option “Single Relay” can be any of the following selections: Electro-Mechanical Relay, Solid-State Relay or Open Collector Output.

Table 2-5 Universal Output Functionality and Restrictions

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Output Algorithm

Output 1/2

Function of

Function of Other Outputs

Type

Option

Output 1/2

Output #3

Output #4

Auxiliary Output

Time Simplex

Single Relay

Output 1

Alarm 2

Alarm 1

Not Needed

Current Output

INU

Output 1

Alarm 1

Not Needed

Dual Relay

Output 1

Alarm 2

Alarm 1

Not Needed

Time Duplex or

Single Relay

Output 1

Output 2

Alarm 1

Not Needed

TPSC or Position

Current Output

INU

Output 2

Output 1

Not Needed

Proportional

Dual Relay

Outputs 1 and

Alarm 2

Alarm 1

Not Needed

2

Current Simplex

Single Relay

INU

Alarm 2

Alarm 1

Output 1

Current Output

Output 1

Alarm 2

Alarm 1

Not Needed

Dual Relay

INU

Alarm 2

Alarm 1

Output 1

Current Dup. 100%

Single Relay

INU

Alarm 2

Alarm 1

Outputs 1 and 2

Current = COOL

Current Output

Outputs 1 and

Alarm 2

Alarm 1

Not Needed

and HEAT

2

Dual Relay

INU

Alarm 2

Alarm 1

Outputs 1 and 2

Current Duplex

Single Relay

N/A

N/A

N/A

N/A

50%

Current Output

Output 1

Alarm 2

Alarm 1

Output 2

Current = HEAT

Dual Relay

N/A

N/A

N/A

N/A

Aux Out = COOL

Current/Time

Single Relay *

Output 1

Output 2

Alarm 1

Output 2

Current = COOL

Current Output

Output 2

Output 2

Alarm 1

Not Needed

Time = HEAT

Dual Relay *

Outputs 1 & 2

Alarm 2

Alarm 1

Output 2

Time/Current

Single Relay *

Output 1

Output 2

Alarm 1

Output 1

Time = COOL

Current Output

Output 1

Output 2

Alarm 1

Not Needed

Current = HEAT

Dual Relay *

Outputs 1 & 2

Alarm 2

Alarm 1

Output 1

TPSC = Three Position Step Control

N/A = Not Available – This output algorithm type cannot be performed with this Output 1/2 option.

INU = Installed, Not Used – The installed Output 1/2 option is not used for the configured output algorithm type.

Not Needed = Auxiliary Output is Not Needed to provide the desired output algorithm and can be used for another purpose. With the proper configuration, Auxiliary Output could also be used as a substitute for the Current Output.

*To obtain this output algorithm type with these Output 1/2 Options: 1) Configure the OUTALG selection as “TIME D”; 2) Configure Auxiliary Output for “OUTPUT” and; 3) Scale the Auxiliary Output as necessary for the desired output algorithm type. For these selections, the Output 1 (HEAT) and Output 2 (COOL) signals will be present both on the Auxiliary Output and on the two relays normally used for Time Duplex.

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Wiring the Controller

			7
		10	19
1	L1	11	20	4
	L2/N	12	21
	4	13	22
2	5	14	23	5
	6	15	24
3	7	16	25
	8	17	26	6
	9	18	27

8

See table for callout details

Figure 2-4 Composite Wiring Diagram

Callout

Details

1AC/DC Line Voltage Terminals. See Figure 2-5.

2Output 3 Terminals. See Figure 2-8 through Figure 2-14.

3Output 4 Terminals. See Figure 2-8 through Figure 2-14.

4Outputs 1 and 2 Terminals. See Figure 2-8 through Figure 2-14.

5Input #2 Terminals. See Figure 2-7.

6Input #1 Terminals. See Figure 2-6.

7Aux. Output and Digital Inputs Terminals. See Figure 2-17.

8Communications Terminals. See Figure 2-15 and Figure 2-16.

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	1	Earth
3		Ground	10	19
	2	Hot
AC/DC			11	20
		L1
Line		Neutral	12	21
Voltage		L2/N
		4	13	22
		5	14	23
		6	15	24
		7	16	25
		8	17	26
		9	18	27

1PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is installed, shall be in accordance with National and local electrical codes. To minimize

electrical noise and transients that may adversely affect the system, supplementary bonding of the controller enclosure to local ground using a No. 12 (4 mm2) copper conductor is recommended. Before powering the controller, see “Prelimnary Checks” in this section of the Product Manual.

2It 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 installation.

3CAUTION Applying 90-264 Vac to an instrument rated for 24 Vac/dc will severely

damage the instrument and is a fire and smoke hazard.

Figure 2-5 Mains Power Supply

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Input #1

	Thermocouple	RTD	Millivolt or Volts
			except 0-10 Volts
	Use Thermocouple
	extension wire only		source		25 R
	25 R	25 R
	3			+
	26 +	26 +	mV or		26 +
			Volt
	27 –	27 –	source	–	27 –
	0-10 Volts	Milliamps	Thermocouple Differential

0–10 +		100K 1
Volt	1	2
source

–100K 3

							Use Thermocouple
25	R	–				25 R	extension wire only		25	R
							+
		Xmitter		1
26	+	+				26 +		4	26	+
			250		Ω		–
								2
27	–		Power			27 –	–		27	–
			+ –
			Supply				+

1The 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.

2Splice 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.

3This 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.

4The millivolt values for the Thermocouple Differential Input are for a pair of J thermocouples at an ambient temperature mean of 450°F / 232°C.

Figure 2-6 Input 1 Connections

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Input #2

Thermocouple	RTD		Millivolt or Volts
			except 0-10 Volts
Use Thermocouple
extension wire only	22	R	source		22 R
22 R
3				+
23 +	23	+	mV or		23 +
			Volt
24 –	24	–	source	–	24 –
0-10 Volts	Milliamps		Thermocouple Differential

0–10	+	100K 1
Volt	1	2
source

–100K 3

					Use Thermocouple
22	R	–		22 R	extension wire only		22	R
					+
		Xmitter	1
23	+	+		23 +	–		23	+
			Ω
		250				2
24	–	Power		24 –	–		24	–
		+ –
		Supply			+

Slidewire Input

(for Position Proportional Control or Three Position Step Control)

	4
Open	22	R
Wiper	23	+
Close	24	–

1The 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.

2Splice 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.

3This 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 theother instrument to also drive this controller.

4 Input 2 is used to measure the Slidewire Input for Position Proportional Control.	xxxx

Figure 2-7 Input 2 Connections

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			Time Simplex
						19
				Output	N.C.			Load
			L1			20	Relay Load
				Relay#1
					N.O.			Supply
			L2/N			21	To terminal	Power
			4			22	19 or 21	2
Load		Relay Load		N.C. Alarm
			5			23
Supply		To terminal		N.O.Relay#2
Power			6			24
	2	4 or 6
			7			25
Load		Relay Load		N.C. Alarm
			8			26
Supply		To terminal		N.O. Relay#1
Power			9			27
	2	7 or 9

			Time Duplex
						19
				Output	N.C.
			L1			20
				Relay#1
					N.O.
			L2/N			21
Load		Relay Load	4	N.C. Output		22
						23
			5	N.O.Relay#2
Supply		To terminal
Power			6	1		24
	2	4 or 6
			7			25
Load		Relay Load		N.C. Alarm
			8	N.O. Relay#1		26
Supply		To terminal
Power			9			27
	2	7 or 9

	Relay Load	Load
		Supply

To terminal	Power
19 or 21	2

1 Alarm #2 is not available with Time Proportional Duplex or Three Position Step Control unless the Dual Relay Option is used.

2Electromechanical relays are rated at 5 Amps @ 120 Vac or 240 Vac or 30 Vdc. Customer should size fuses accordingly. Use Fast Blo fuses only.

Figure 2-8 Electromechanical Relay Output

See Table 2-5 for relay terminal connections for other Output Algorithm Types.

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			Time Simplex					1
						19	Dummy Resistor
			L1	Output		20	Relay Load	Load
				Relay#1
					N.O.			Supply
			L2/N			21	2	Power
			4	N.C. Alarm		22
Load		Relay Load
			5	N.O. Relay#2		23
Supply
Power		To terminal	6			24
	3	4 or 6
			7			25
Load		Relay Load		N.C. Alarm
			8	Relay#1		26
Supply		To terminal		N.O.
Power			9			27
	3	7 or 9
			Time Duplex				1
						19	Dummy Resistor

		L1	Output		20	Relay Load	Load
			Relay#1
	1			N.O.			Supply
		L2/N			21		Power
	Dummy Resistor					2
					22
		4	Output
Load	Relay Load
Supply		5	Relay#2		23
			N.O.
Power	2	6			24
		7			25
Load	Relay Load		N.C. Alarm
		8	Relay#1		26
Supply			N.O.
	To terminal	9			27
Power
	7 or 9
	3

If the load current is less than the minimum rated value of 20 mA, then there may be residual voltage across both

1ends 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.

2	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.
3	Electromechanical relays are rated at 5 Amps @ 120 Vac or 240 Vac or 30 Vdc.
	Customer should size fuses accordingly. Use Fast Blo fuses only.

Figure 2-9 Solid State Relay Output

See Table 2-5 for relay terminal connections for other Output Algorithm Types.

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Time Simplex

					19		Customer Supplied
							Electromechanical relay
			L1	+	20	+	+
			L2/N	Output #1	21	–
				1 –			–
			4		22
Load				N.C. Alarm		Customer Supplied
		Relay Load	5	Relay#2	23	Solid-State relay
Supply		To terminal		N.O.
Power			6		24
	3	4 or 6			25
			7
Load		Relay Load		N.C. Alarm
			8	Relay#1	26
Supply				N.O.
		To terminal
Power			9		27
	3	7 or 9

			Time Duplex						Customer Supplied
							19		Electromechanical relay
						+			+
			L1				20	+
					Output #1
	Customer Supplied		L2/N			1 –	21	–	–
	Electromechanical relay		4				22	Customer Supplied
	+			+
		+	5				23	Solid-State relay
				Output #2
	–	–	6	–	1	2	24
		Customer Supplied
			7				25
Load		Solid-State relay			N.C. Alarm
		Relay Load	8			Relay#1	26
Supply					N.O.
		To terminal	9				27
Power
		7 or 9
		3
1	CAUTION	Open collector outputs are internally powered at +30 Vdc. Connecting an external
		power supply will damage the controller.

2 Alarm #2 is not available with Time Proportional Duplex or Three Position Step Control unless the Dual Relay option is used.

3Electromechanical relays are rated at 5 Amps @ 120 Vac or 240 Vac or 30 Vdc. Customer should size fuses accordingly. Use Fast Blo fuses only.

Figure 2-10 Open Collector Output

See Table 2-5 for relay terminal connections for other Output Algorithm Types.

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Time Duplex with a Dual Relay Board

			Out Relay#2			19	Cool Relay Load	Load
					N.O.
			L1 Out Relay#1		N.O.20		Heat Relay Load	Supply
			L2/N			21		Power
Load			4	N.C. Alarm		22	1
		Relay Load	5			23
				N.O. Relay#2
Supply		To terminal
Power			6			24
	2	4 or 6				25
			7
Load				N.C. Alarm
		Relay Load	8			26
Supply				N.O. Relay#1
		To terminal
Power			9			27
	2	7 or 9

1Dual Electromechanical relays are rated at 2 Amps @120 Vac or 240 Vac or 30 Vdc. Customer should size fuses accordingly. Use Fast Blo fuses only.

2Electromechanical relays are rated at 5 Amps @120 Vac or 240 Vac or 30 Vdc. Customer should size fuses accordingly. Use Fast Blo fuses only.

Figure 2-11 Dual Electromechanical Relay Option Output

See Table 2-5 for relay terminal connections for other Output Algorithm Types.

					19	+
			L1		20	Current Output	Controller Load
			L2/N		21	4–20 mA	0-1000 ohms
						–
			4		22
Load		Relay Load		N.C. Alarm
			5		23
				N.O. Relay#2
Supply		To terminal
Power			6		24
	2	4 or 6
			7		25
Load		Relay Load		N.C. Alarm
			8	Relay#1	26
Supply				N.O. 1
		To terminal
Power			9		27
	2	7 or 9

1When the instrument has the Current Output as shown, no Alarms are available when using the Time Proportional Duplex or Three Position Step Control Output Algorithms, as these outputs require both available relays.

2Electromechanical relays are rated at 5 Amps @120 Vac or 240 Vac or 30 Vdc Customer should size fuses accordingly. Use Fast Blo fuses only.

Figure 2-12 Current Output

See Table 2-5 for relay terminal connections for other Output Algorithm Types.

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Figure 2-13 Position Proportional or Three Position Step Control Connection, Models DC3200-EE or DC3200-AA

Figure 2-14 Position Proportional or Three Position Step Control Connections, Model DC3200-R_

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COMMUNICATION MASTER

D+ (B) SHLD D– (A)

1 2

16 SHLD	SHLD
17 D+ (B)	D+
18 D– (A)	D–

120 OHMS

				Connect shield
TO OTHER				to ground at one
COMMUNICATION				end only.
CONTROLLERS
D–	D+

120 OHMS ON LAST LEG

1 Do not run the communications lines in the same conduit as AC power. 2 Use shielded twisted pair cables (Belden 9271 Twinax or equivalent).

Figure 2-15 RS-422/485 Communications Option Connections

COMMUNICATION MASTER	3
OR SWITCH

SHLD TXDR –+ TXD+R - TRXD+– TRXD-+

1

1414SHLDSHLD

2

1515RXDRXD+

16 RXD –

16 RXD-

1717TXDTXD+

1818TXDTXD–-

1Do not run the communications lines in the same conduit as AC power. Correct connections may require the use of an Ethernet cross-over cable.

2Use Shielded twisted-pair, Category 5 (STP CAT5) Ethernet cable.

3Use Switch rather than Hub to maximize performance.

Figure 2-16 Ethernet Communications Option Connections

Figure 2-16 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.

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