Honeywell UDC2500

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4/07 UDC2500 Universal Digital Controller Product Manual 227

Main Page

About this Document3
World Wide Web3
Symbol Definitions4
Table of Contents5
Introduction15
Overview15
Figure 1-1 UDC2500 Operator Interface (All Display Items Shown)16
Function of Displays and Keys17
Process Instrument Explorer Software18
Figure 1-2 Screen Capture of Process Instrument Explorer Running on a Pocket PC18
CE Conformity (Europe)19
Figure 1-3 Depiction of Infrared Communications19
Installation21
Overview21
Condensed Specifications22
Table 2-1 Condensed Specifications22
Model Number Interpretation26
Figure 2-1 Model Number Interpretation27
Control and Alarm Relay Contact Information28
Table 2-2 Control Relay Contact Information28
Table 2-3 Alarm Relay Contact Information28
Mounting29
Figure 2-2 Mounting Dimensions (Not to Scale)29
Table 2-4 Mounting Procedure30
Figure 2-3 Mounting Methods30
Wiring31
Electrical Considerations31
Table 2-5 Permissible Wiring Bundling32
Wiring Diagrams33
Table 2-6 Universal Output Functionality and Restrictions34
Figure 2-4 Composite Wiring Diagram35
Figure 2-5 Mains Power Supply36
Figure 2-6 Input 1 Connections37
Figure 2-7 Input 2 Connections38
Figure 2-8 Electromechanical Relay Output38
Figure 2-9 Solid State Relay Output39
Figure 2-10 Open Collector Output40
Figure 2-11 Dual Electromechanical Relay Option Output41
Figure 2-12 Current Output41
Figure 2-13 Three Position Step Control Connections W/O Dual Relay Option42
Figure 2-14 Three Position Step Control Connections with Dual Relay Option42
Figure 2-15 RS-422/485 Communications Option Connections43
Figure 2-16 Ethernet Communications Option Connections43
Table 2-7 Terminals for Connecting a UDC to a MDI Compliant Hub or Switch44
Table 2-8 Terminals for Connecting a UDC Directly to a PC Utilizing a Straight-Through Cable44
Figure 2-17 Auxiliary Output and Digital Inputs Option Connections44
Figure 2-19 Transmitter Power for 4-20 Ma - 2 Wire Transmitter Using Auxiliary Output45
Configuration46
Overview46
Table 3-1 Configuration Topics46
Configuration Prompt Hierarchy47
Table 3-2 Configuration Prompt Hierarchy47
Configuration Procedure48
Table 3-3 Configuration Procedure48
Tuning Set up Group49
Table 3-4 TUNING Group (Numeric Code 100) Function Prompts49
SP Ramp Set up Group53
Table 3-5 SPRAMP Group (Numeric Code 200) Function Prompts53
Accutune Set up Group57
Table 3-6 ATUNE Group (Numeric Code 300) Function Prompts58
Algorithm Set up Group60
Table 3-7 ALGOR Group (Numeric Code 400) Function Prompts60
Output Set up Group65
Table 3-8 OUTPUT Group (Numeric Code 500) Function Prompts65
Input 1 Set up Group69
Table 3-9 INPUT 1 Group (Numeric Code 600) Function Prompts69
Input 2 Set up Group73
Table 3-10 INPUT2 Group (Numeric Code 700) Function Prompts73
Control Set up Group75
Table 3-11 Table 3-12 CONTRL Group (Numeric Code 800) Function Prompts75
Options Group81
Table 3-13 OPTION Group (Numeric Code 900) Function Prompts81
Communications Group87
Table 3-14 Communications Group (Numeric Code 1000) Function Prompts87
Alarms Set up Group90
Table 3-15 ALARMS Group (Numeric Code 1100) Function Prompts90
Display Set up Group96
Table 3-16 DISPLY Group (Numeric Code 1200) Function Prompts96
Tool Ethernet and Email Configuration Screens98
Figure 3-1 Ethernet Configuration Screen98
Figure 3-2 Email Configuration Screen99
Configuration Record Sheet101
Introduction103
Monitoring and Operating the Controller103
Overview103
Figure 4-1 Operator Interface103
Operator Interface104
Entering a Security Code104
Lockout Feature105
Table 4-1 Procedure to Enter a Security Code105
Monitoring Your Controller107
Annunciators107
Table 4-2 Annunciators107
Viewing the Operating Parameters108
Table 4-3 Lower Display Key Parameter Prompts108
Diagnostic Messages109
Table 4-4 Diagnostic Messages109
Figure 4-2 Functional Overview Block Diagram of the UDC2500 Controller110
Single Display Functionality111
Table 4-5 Single Display Parameters112
Start up Procedure for Operation113
Table 4-6 Procedure for Starting up the Controller113
Control Modes114
Mode Definitions114
Table 4-7 Control Mode Definitions114
What Happens When You Change Modes115
Setpoints115
Table 4-8 Changing Control Modes (Dual Display Only)115
Table 4-9 Procedure for Changing the Local Setpoints115
Timer116
Table 4-10 Procedure for Switching between Setpoints116
Accutune III118
Tune for Simplex Outputs119
Tune for Duplex (Heat/Cool)119
Table 4-11 Procedure for Starting "TUNE119
Using AUTOMATIC TUNE at Start-Up for Duplex (Heat/Cool)120
Using BLENDED TUNE at Start-Up for Duplex (Heat/Cool)120
Table 4-12 Procedure for Using AUTOMATIC TUNE at Start-Up for Duplex Control120
Using MANUAL TUNE at Start-Up for Duplex (Heat/Cool)121
Table 4-13 Procedure for Using BLENDED TUNE at Start-Up for Duplex Control121
Table 4-14 Procedure for Using MANUAL TUNE for Heat Side of Duplex Control121
Table 4-15 Procedure for Using MANUAL TUNE for Cool Side of Duplex Control122
Error Codes123
Table 4-16 Procedure for Accessing Accutune Error Codes123
Table 4-17 Accutune Error Codes123
Fuzzy Overshoot Suppression124
Using Two Sets of Tuning Constants124
Table 4-18 Set up Procedure125
Alarm Setpoints126
Table 4-19 Procedure for Switching PID SETS from the Keyboard126
Table 4-20 Procedure for Displaying Alarm Setpoints126
Three Position Step Control Algorithm127
Table 4-21 Procedure for Displaying 3Pstep Motor Position127
Setting a Failsafe Output Value for Restart after a Power Loss128
Table 4-22 Procedure for Setting a Failsafe Value128
Setting Failsafe Mode129
Setpoint Rate/Ramp/Program Overview129
Table 4-23 Procedure for Setting a Failsafe Mode129
Setpoint Ramp130
Table 4-24 Running a Setpoint Ramp130
Setpoint Rate131
Setpoint Ramp/Soak Programming132
Table 4-25 Program Contents132
Figure 4-3 Ramp/Soak Profile Example135
Figure 4-4 Program Record Sheet136
Table 4-26 Run/Monitor Functions137
Tool Maintenance Screens139
Figure 4-5 Maintenance Data Menu139
Figure 4-6 Loop Data Maintenance Screen140
Figure 4-7 Alarm Details Maintenance Screen141
Figure 4-8 Digital Input Details Screen142
Figure 4-9 Status Data Maintenance Screen143
Figure 4-10 Ethernet Status Maintenance Screen144
Configuring Your Ethernet Connection145
Figure 4-11 IR Communications Address145
Figure 4-12 Online Configuration146
Figure 4-13 Configuration Upload in Progress146
Figure 4-14 Ethernet Communications Type Selection147
Figure 4-15 Ethernet Communications Address148
Figure 4-16 Configuration Upload in Progress149
Input Calibration150
Overview150
Minimum and Maximum Range Values151
Table 5-1 Voltage, Milliamp and Resistance Equivalents for Input 1 Range Values151
Preliminary Information153
Table 5-2 Voltage and Milliamp Equivalents for Input 2 Range Values153
Table 5-3 Equipment Needed153
Figure 5-1 Input 1 and Input 2 Wiring Terminals153
Input 1 Set up Wiring154
Table 5-4 Set up Wiring Procedure for Thermocouple Inputs Using an Ice Bath154
Figure 5-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath154
Table 5-5 Set up Wiring Procedure for Thermocouple Inputs Using Thermocouple Source155
Table 5-6 Set up Wiring Procedure for RTD Inputs155
Figure 5-3 Wiring Connections for Thermocouple Inputs Using Thermocouple Source155
Figure 5-4 Wiring Connections for RTD (Resistance Thermometer Device)155
Table 5-7 Set up Wiring Procedure for Radiamatic, Millivolts, Volts or Thermocouple Differential Inputs156
Figure 5-5 Wiring Connections for Radiamatic, Thermocouple Differential, Millivolts or Volts156
Table 5-8 Set up Wiring Procedure for 0 to 10 Volts157
Table 5-9 Set up Wiring Procedure for Milliampere Inputs157
Figure 5-6 Wiring Connections for 0 to 10 Volts157
Figure 5-7 Wiring Connections for 0 to 20 Ma or 4 to 20 Ma Inputs157
Input 1 Calibration Procedure158
Table 5-10 Input 1 Calibration Procedure (Numeric Code 10000)158
Input 2 Set up Wiring160
Table 5-11 Set up Wiring Procedure for 0 to 20 Ma or 4 to 20 Ma Inputs - Input 2160
Figure 5-8 Wiring Connections for 0 to 20 Ma or 4 to 20 Ma Input - Input 2160
Input 2 Calibration Procedure161
Table 5-12 Set up Wiring Procedure for 0 to 2 Volts, 0 to 5 Volts, or 1 to 5 Volts - Input 2161
Figure 5-9 Wiring Connections for 0 to 2 Volts, 0 to 5 Volts or 1 to 5 Volts Input - Input 2161
Table 5-13 Input 2 Calibration Procedure (Numeric Code 20000)162
Restore Input Factory Calibration163
Table 5-14 Restore Factory Calibration163
Output Calibration165
Overview165
Current Output Calibration166
Table 6-1 Set up Wiring Procedure for Current Output166
Figure 6-1 Wiring Connections for Calibrating Current Output166
Table 6-2 Current Output Calibration Procedure (Numeric Code 30000)167
Auxiliary Output Calibration168
Table 6-3 Set up Wiring Procedure for Auxiliary Output168
Figure 6-2 Wiring Connections for Calibrating Auxiliary Output168
Table 6-4 Auxiliary Output Calibration Procedure (Numeric Code 50000)169
Restore Output Factory Calibration Procedure170
Table 6-5 Restore Factory Calibration Procedure170
Troubleshooting/Service172
Overview172
Table 7-16 Software Upgrades172
Troubleshooting Aids173
Table 7-1 Procedure for Identifying the Software Version174
Power-Up Tests175
Status Tests175
Table 7-2 Procedure for Displaying the Status Test (Numeric Code 1200) Results175
Background Tests176
Table 7-3 Background Tests176
Controller Failure Symptoms178
Table 7-4 Controller Failure Symptoms178
Troubleshooting Procedures179
Table 7-5 Troubleshooting Power Failure Symptoms180
Table 7-6 Troubleshooting Current Output Failure180
Table 7-7 Troubleshooting Three Position Step Control Output Failure181
Table 7-8 Troubleshooting Time Proportional Output Failure182
Table 7-9 Troubleshooting Current/Time or Time/Current Proportional Output Failure183
Table 7-10 Troubleshooting Alarm Relay Output Failure184
Table 7-11 Troubleshooting a Keyboard Failure185
Table 7-12 Troubleshooting a RS-485 Communications Failure186
Table 7-13 Troubleshooting an Ethernet Communications Failure187
Table 7-14 Troubleshooting Auxiliary Output Failure187
Restoring Factory Configuration188
Table 7-15 Restoring Factory Configuration188
Software Upgrades189
Parts List191
Exploded View191
Figure 8-1 UDC2500 Exploded View191
Table 8-1 Parts Identification192
Table 8-2 Parts Not Shown192
Table 8-3 Software Upgrades (See Section 7.9)192
Removing the Chassis193
Modbus Rtu Function Codes194
Overview194
General Information194
Table 9-1 Integer Parameter Type195
Table 9-2 Floating Point Parameter Type195
Function Code 20 (14H) - Read Configuration Reference Data196
Table 9-3 Register Address Format for Function Code 20197
Read Configuration Examples198
Function Code 21 (15H) - Write Configuration Reference Data200
Table 9-4 Register Address Format for Function Code 21201
Write Configuration Examples202
Modbus Read, Write and Override Parameters Plus Exception Codes203
Overview203
Reading Control Data204
Read Software Options Status205
Table 10-1 Control Data Parameters205
Table 10-2 Option Status205
Figure 10-1 Software Option Status Information205
Miscellaneous Read Onlys206
Register Addresses for Read Onlys206
Setpoint Program Read Only Information206
Table 10-3 Miscellaneous Read Onlys206
Table 10-4 Setpoint Program Read Only Information206
Setpoints207
Table 10-5 Setpoint Code Selections207
Table 10-6 Setpoint Associated Parameters207
Using a Computer Setpoint (Overriding Controller Setpoint)208
Table 10-7 Computer Setpoint Selection208
Table 10-8 Computer Setpoint Associated Parameters209
Configuration Parameters210
Tuning210
Table 10-9 Set-Up Group - Tuning210
SP Ramp/Rate/Program212
Table 10-10 Set-Up Group - Setpoint Ramp/Rate212
Accutune215
Table 10-11 Set-Up Group - Accutune215
Algorithm216
Table 10-12 Set-Up Group - Algorithm216
Output Algorithms217
Table 10-13 Set-Up Group - Output217
Input 1218
Table 10-14 Set-Up Group - Input 1218
Input 2221
Table 10-15 Set-Up Group - Input 2221
Control223
Table 10-16 Set-Up Group - Control223
Options225
Table 10-17 Set-Up Group - Options225
Communications227
Table 10-18 Set-Up Group - Communications227
Alarms228
Table 10-19 Set-Up Group - Alarms228
Display231
Table 10-20 Set-Up Group - Display231
Modbus RTU Exception Codes232
Table 10-21 Modbus RTU Data Layer Status Exception Codes233
Ethernet Tcp/Ip234
Overview234
Further Information235
Modbus RTU Serial Communications235
Modbus Messaging on TCP/IP235
How to Apply Digital Instrumentation in Severe Electrical Noise Environments235
Index236
Sales and Service240

Honeywell UDC2500 - Page 241

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