Honeywell UDC2500 User manual

Industrial Measurement and Control
UDC2500
Universal Digital Controller
Limit Control Model
Product Manual
51-52-25-118
May 2004

UDC2500 Universal Digital Limit ControllerProduct Manual ii
Notices and Trademarks
Copyright 2004 by Honeywell
Revision 1 May 2004
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.
Industrial Measurement and Control
Honeywell
1100 Virginia Drive
Fort Washington, PA 19034
UDC2500 is a U.S. registered trademark of Honeywell
Other brand or product names are trademarks of their respective owners.

UDC2500 Universal Digital Limit ControllerProduct Manual iii
About This Document
Abstract
This document provides descriptions and procedures for the Installation, Configuration, Operation, and Troubleshooting of
your UDC2500 Controller.
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
Industrial Measurement and Control http://www.honeywell.com/imc
Telephone
Contact us by telephone at the numbers listed below.
Organization Phone Number
United States and Canada Honeywell 1-800-423-9883 Tech. Support
1-888-423-9883 Q&A Faxback
(TACFACS)
1-800-525-7439 Service

UDC2500 Universal Digital Limit ControllerProduct Manual iv
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.

v UDC2500 Universal Digital Limit ControllerProduct Manual
Contents
1INTRODUCTION ...................................................................................................1
1.1 Overview.........................................................................................................................................1
1.1.1 Function of keys...................................................................................................................4
1.2 Process Instrument Explorer Software............................................................................................5
1.3 CE Conformity (Europe).................................................................................................................7
2INSTALLATION.....................................................................................................9
2.1 Overview.........................................................................................................................................9
2.2 Condensed Specifications .............................................................................................................10
2.3 Model Number Interpretation .......................................................................................................13
2.4 Limit and Alarm Relay Contact Information................................................................................15
2.5 Mounting.......................................................................................................................................16
2.6 Wiring ...........................................................................................................................................18
2.6.1 Electrical Considerations................................................................................................18
2.7 Wiring Diagrams...........................................................................................................................20
2.8 Limit Control Application Diagram..............................................................................................27
3CONFIGURATION............................................................................................... 28
3.1 Overview.......................................................................................................................................28
3.2 Configuration Prompt Hierarchy ..................................................................................................29
3.3 Configuration Procedure...............................................................................................................30
3.4 Lock Set Up Group .......................................................................................................................31
3.5 Limit Set Up Group ......................................................................................................................32
3.6 Input 1 Set Up Group....................................................................................................................33
3.7 Options Group...............................................................................................................................37
3.8 Communications Group ................................................................................................................39
3.9 Alarms Set Up Group....................................................................................................................43
3.10 Display Set Up Group ...............................................................................................................47
3.11 Configuration Record Sheet ......................................................................................................48
4OPERATING 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

UDC2500 Universal Digital Limit ControllerProduct Manual vi
4.6 Operating Your Limit Controller ..................................................................................................54
4.7 Alarm Setpoints ............................................................................................................................57
5INPUT CALIBRATION.........................................................................................58
5.1 Overview.......................................................................................................................................58
5.2 Minimum and Maximum Range Values .......................................................................................59
5.3 Preliminary Information................................................................................................................61
5.4 Input 1 Set Up Wiring...................................................................................................................62
5.5 Input 1 Calibration Procedure.......................................................................................................66
5.6 Restore Factory Calibration ..........................................................................................................67
6OUTPUT CALIBRATION..................................................................................... 69
6.1 Overview.......................................................................................................................................69
6.2 Auxiliary Output Calibration ........................................................................................................69
7TROUBLESHOOTING/SERVICE........................................................................ 72
7.1 Overview.......................................................................................................................................72
7.2 Troubleshooting Aids....................................................................................................................73
7.3 Power-up Tests..............................................................................................................................75
7.4 Status Tests ...................................................................................................................................75
7.5 Background Tests..........................................................................................................................76
7.6 Controller Failure Symptoms........................................................................................................78
7.7 Troubleshooting Procedures .........................................................................................................79
7.8 Restoring Factory Configuration ..................................................................................................85
8PARTS LIST ........................................................................................................ 86
8.1 Exploded View..............................................................................................................................86
8.2 Removing the chassis....................................................................................................................88
9MODBUS .............................................................................................................89
9.1 Overview.......................................................................................................................................89
10 ETHERNET TCP/IP .............................................................................................90
10.1 Overview ...................................................................................................................................90
11 FURTHER INFORMATION.................................................................................. 91
11.1 Modbus Messaging on TCP/IP..................................................................................................91
11.2 How to Apply Digital Instrumentation in Severe Electrical Noise Environments....................91

vii UDC2500 Universal Digital Limit ControllerProduct Manual
12 INDEX..................................................................................................................92
13 SALES AND SERVICE........................................................................................ 94

UDC2500 Universal Digital Limit ControllerProduct Manual viii
Tables
Table 2-1 Condensed Specifications ____________________________________________________ 10
Table 2-2 Limit Relay Contact Information _______________________________________________ 15
Table 2-3 Alarm Relay Contact Information ______________________________________________ 15
Table 2-4 Mounting Procedure_________________________________________________________ 17
Table 2-5 Permissible Wiring Bundling__________________________________________________ 19
Table 3-1 Configuration Topics ________________________________________________________ 28
Table 3-2 Configuration Prompt Hierarchy _______________________________________________ 29
Table 3-3 Configuration Procedure _____________________________________________________ 30
Table 3-4 LOCK Group Function Prompts _______________________________________________ 31
Table 3-5 LIMIT Group Function Prompts _______________________________________________ 32
Table 3-6 INPUT 1 Group Function Prompts _____________________________________________ 33
Table 3-7 OPTION Group Function Prompts _____________________________________________ 37
Table 3-8 Communications Group Function Prompts _______________________________________ 39
Table 3-9 ALARMS Group Function Prompts ____________________________________________ 43
Table 3-10 DISPLY Group (Numeric Code 1200) Function Prompts___________________________ 47
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 _______________ 59
Table 5-2 Equipment Needed__________________________________________________________ 61
Table 5-3 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath _________________ 62
Table 5-4 Set Up Wiring Procedure for Thermocouple Inputs using Thermocouple Source _________ 63
Table 5-5 Set Up Wiring Procedure for RTD Inputs ________________________________________ 63
Table 5-6 Set Up Wiring Procedure for Radiamatic, Millivolts, Volts or Thermocouple Differential Inputs
(Except 0-10 Volts) ______________________________________________________________ 64
Table 5-7 Set Up Wiring Procedure for 0 to 10 Volts _______________________________________ 65
Table 5-8 Set Up Wiring Procedure for Milliampere Inputs __________________________________ 65
Table 5-9 Input 1 Calibration Procedure _________________________________________________ 66
Table 5-10 Restore Factory Calibration __________________________________________________ 68
Table 6-1 Set Up Wiring Procedure for Auxiliary Output ____________________________________ 70
Table 6-2 Auxiliary Output Calibration Procedure _________________________________________ 71
Table 7-1 Procedure for Identifying the Software Version ___________________________________ 74
Table 7-2 Procedure for Displaying the Status Test Results __________________________________ 75
Table 7-3 Background Tests___________________________________________________________ 76
Table 7-4 Controller Failure Symptoms__________________________________________________ 78
Table 7-5 Troubleshooting Power Failure Symptoms _______________________________________ 80
Table 7-6 Troubleshooting Latching Output Relay Failure ___________________________________ 81
Table 7-7 Troubleshooting Alarm Relay Output Failure _____________________________________ 81
Table 7-8 Troubleshooting a Keyboard Failure ____________________________________________ 82
Table 7-9 Troubleshooting a RS-485 Communications Failure________________________________ 83
Table 7-10 Troubleshooting Auxiliary Output Failure ______________________________________ 84
Table 7-11 Restoring Factory Configuration ______________________________________________ 85
Table 8-1 Parts Identification __________________________________________________________ 87
Table 8-2 Parts Not Shown____________________________________________________________ 87

ix UDC2500 Universal Digital Limit ControllerProduct Manual
Figures
Figure 1-1 UDC2500 Operator Interface __________________________________________________ 3
Figure 1-2 Screen capture of Process Instrument Explorer running on a Pocket PC _________________ 5
Figure 1-3 Depiction of infrared communications ___________________________________________ 6
Figure 2-1 Model Number Interpretation _________________________________________________ 14
Figure 2-2 Mounting Dimensions (not to scale)____________________________________________ 16
Figure 2-3 Mounting Method __________________________________________________________ 17
Figure 2-4 Composite Wiring Diagram __________________________________________________ 20
Figure 2-5 Mains Power Supply________________________________________________________ 21
Figure 2-6 Input 1 Connections ________________________________________________________ 22
Figure 2-7 Electromechanical Relay Output ______________________________________________ 23
Figure 2-8 Solid State Relay Output ____________________________________________________ 23
Figure 2-9 Open Collector Output ______________________________________________________ 24
Figure 2-10 RS-422/485 Communications Option Connections _______________________________ 24
Figure 2-11 Ethernet Communications Option Connections __________________________________ 25
Figure 2-12 Auxiliary Output and Digital Inputs Option Connections __________________________ 25
Figure 2-13 Transmitter Power for 4-20 mA — 2 wire Transmitter Using Open Collector Alarm 2 Output26
Figure 2-14 Transmitter Power for 4-20 mA — 2 Wire Transmitter Using Auxiliary Output ________ 26
Figure 2-15 Limit Controller Application Diagram _________________________________________ 27
Figure 4-1 Operator Interface__________________________________________________________ 50
Figure 5-1 Input 1 Wiring Terminals ____________________________________________________ 61
Figure 5-2 Wiring Connections for Thermocouple Inputs Using an Ice Bath _____________________ 62
Figure 5-3 Wiring Connections for Thermocouple Inputs Using Thermocouple Source ____________ 63
Figure 5-4 Wiring Connections for RTD (Resistance Thermometer Device) _____________________ 63
Figure 5-5 Wiring Connections for Radiamatic, Millivolts, Volts or Thermocouple Differential (Except 0 to 10
Volts) _________________________________________________________________________ 64
Figure 5-6 Wiring Connections for 0 to 10 Volts___________________________________________ 65
Figure 5-7 Wiring Connections for 0 to 20 mA or 4 to 20 mA Inputs___________________________ 65
Figure 6-1 Wiring Connections for Calibrating Auxiliary Output ______________________________ 70
Figure 8-1 UDC2500 Exploded View ___________________________________________________ 86

Introduction
UDC2500 Universal Digital Limit ControllerProduct Manual 1
1 Introduction
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).
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.
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.

Introduction
UDC2500 Universal Digital Limit ControllerProduct Manual 2
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.
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.
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
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.

Introduction
UDC2500 Universal Digital Limit ControllerProduct Manual 3
Figure 1-1 UDC2500 Operator Interface

Introduction
UDC2500 Universal Digital Limit ControllerProduct Manual 4
1.1.1 Function of keys
Table 1-1 shows each key on the operator interface and defines its function.
Table 1-1 Function of Keys
Key Function
SET UP
• Places the controller in the Configuration Set Up group select mode.
Sequentially displays Set Up groups and allows the FUNCTION key to
display individual functions in each Set Up group.
FUNCTION
• 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.
LOWER
DISPLAY
• Selects an operating parameter to be shown in the lower display.
MAN-AUTO
RESET
MAN-AUTO This function is not available on the Limit Controller.
RESET Reset the Limit Relay.
SP
SELECT
This function does not function on the Limit Controller
RUN
HOLD
• Acknowledges a latched alarm 1.
• Acknowledges Diagnostic Messages.
• Increases the selected parameter value.
• Decreases the selected parameter value.

Introduction
UDC2500 Universal Digital Limit ControllerProduct Manual 5
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
Infrared communications
The infrared connection provides a non-intrusive wireless connection with the instrument
and maintains NEMA4X AND IP66 integrity.

Introduction
UDC2500 Universal Digital Limit ControllerProduct Manual 6
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.
Figure 1-3 Depiction of infrared communications

Introduction
UDC2500 Universal Digital Limit ControllerProduct Manual 7
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: 51453655
Deviation from the installation conditions specified in this manual, and the special
conditions for CE conformity in Subsection 2.1, may invalidate this product’s conformity
with the Low Voltage and EMC Directives.
ATTENTION
The emission limits of EN61326 are designed to provide reasonable protection
against harmful interference when this equipment is operated in an industrial
environment. Operation of this equipment in a residential area may cause harmful
interference. This equipment generates, uses, and can radiate radio frequency
energy and may cause interference to radio and television reception when the
equipment is used closer than 30 meters (98 feet) to the antenna(e). In special
cases, when highly susceptible apparatus is used in close proximity, the user may
have to employ additional mitigating measures to further reduce the
electromagnetic emissions of this equipment.
WARNING
If this equipment is used in a manner not specified by the manufacturer, the
protection provided by the equipment may be impaired.

Installation
UDC2500 Universal Digital Limit ControllerProduct Manual 9
2 Installation
2.1 Overview
Introduction
Installation of the UDC2500 consists of mounting and wiring the controller according to
the instructions given in this section. Read the pre-installation information, check the
model number interpretation (Subsection 2.3), and become familiar with your model
selections, then proceed with installation.
What’s in this section?
The following topics are covered in this section.
TOPIC See Page
2.1 Overview 9
2.2 Condensed Specifications 10
2.3 Model Number Interpretation 13
2.4 Control and Alarm Relay Contact Information 15
2.5 Mounting 16
2.6 Wiring 18
2.7 Wiring Diagrams
Composite Wiring Diagram
AC Line Voltage
Input 1 Connections
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
20
20
21
22
23
23
24
24
25
25
26
26

Installation
UDC2500 Universal Digital Limit ControllerProduct Manual 10
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
Honeywell recommends that you review and adhere to the operating limits listed in Table
2-1 when you install your controller.
Table 2-1 Condensed Specifications
Analog Input 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: input 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: 100 ohms/leg
100 ohm, 200 ohm and 500 ohm RTD: 100 ohms/leg
100 ohm Low RTD: 10 ohms/leg
Analog Input Signal
Failure Operation
Burnout Selections: Upscale, Downscale
Thermocouple Health: Good, Failing, Failure Imminent or Failed
Stray Rejection Common Mode
AC (50 or 60 Hz): 120 dB (with maximum source impedance of 100 ohms) or ± 1 LSB (least
significant bit) whichever is greater with line voltage applied.
DC: 120 dB (with maximum source impedance of 100 ohms) or a ±1 LSB whichever is
greater with 120 Vdc applied.
DC (to 1 KHz): 80 dB (with maximum source of impedance of 100 ohms) or ±1 LSB
whichever is greater with 50 Vac applied.
Normal Mode
AC (50 or 60 Hz): 60 dB (with 100 % span peak-to-peak maximum)
Digital Inputs (Two)
(Optional)
+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.