Honeywell UDC2800 User manual

UDC2800 Universal Digital Controller
Release 110.2
Product Manual
51-52-25-157
Revision 5.0
June 2022

DISCLAIMER
This document contains Honeywell proprietary information.
Information contained herein is to be used solely for the purpose
submitted, and no part of this document or its contents shall be
reproduced, published, or disclosed to a third party without the
express permission of Honeywell International Sàrl.
While this information is presented in good faith and believed to be
accurate, Honeywell disclaims the implied warranties of
merchantability and fitness for a purpose and makes no express
warranties except as may be stated in its written agreement with and
for its customer.
In no event is Honeywell liable to anyone for any direct, special, or
consequential damages. The information and specifications in this
document are subject to change without notice.
Copyright 2022 - Honeywell International Sàrl
2

3
CONTENTS
Contents 3
Chapter 1 - About this guide 11
Chapter 2 - Introduction 13
Overview 13
Operator Interface 20
Function of Displays 20
Function of Keys 22
PC Software and Mobile Device App 24
Configuration Tool via Bluetooth 25
CE Conformity (Europe) 26
North America 28
FCC 28
Chapter 3 - Installation 30
Overview 31
Condensed Specifications 31
Model Number Interpretation 39
Control and Alarm Relay Contact Information 44
Mounting 45
Physical Considerations 45
Overall Dimensions 46
Dimensions and Mounting 46
Mounting Method 47
Mounting Procedure 48
Wiring 49
Electrical Considerations 49
Contents

Wiring Diagrams 51
Identify Your Wiring Requirements 51
Universal Output Functionality and Restrictions 51
Wiring the Controller 54
Chapter 4 - Configuration 66
Overview 67
Configuration Prompt Hierarchy 67
Configuration Procedure 71
Security Set Up Group 73
Tuning Set Up Group 76
SP Ramp/Program Set Up Group 81
SP PROG2 ~ PROG 8 Set Up Group 88
Accutune Set Up Group 91
Algorithm Set Up Group 94
Output Set Up Group 109
Input 1 Set Up Group 115
Input 2 Set Up Group 121
Control Set Up Group 126
Options Set Up Group 138
Communications Group 148
Alarms Set Up Group 152
Display Set Up Group 160
Input1 Calib Set Up Group 163
Input2 Calib Set Up Group 164
Slidewire Calib Set Up Group 165
Current Calib Set Up Group 166
Auxiliary Calib Set Up Group 167
4
Contents

5
Configuration Record Sheet 167
Chapter 5 - Monitoring and Operating the Controller 174
Overview 175
Operator Interface 175
Entering a Security Code 176
Lockout Feature 177
Monitoring Your Controller 178
Annunciators 178
Viewing the operating parameters 178
Diagnostic Messages 182
Start Up Procedure for Operation 183
Control Modes 184
Mode Definitions 184
What happens when you change modes 185
Setpoints 186
Timer 188
Accutune III 189
Tune for Simplex Outputs 191
Tune for Duplex (Heat/Cool) 192
Using AUTOMATIC TUNE at start-up for Duplex (Heat/Cool) 192
Using BLENDED TUNE at start-up for Duplex (Heat/Cool) 193
Using MANUAL TUNE at start-up for Duplex (Heat/Cool) 194
Error Codes 195
Fuzzy Overshoot Suppression 197
Using Four Sets of Tuning Constants 198
Auto/Manual Station 201
Alarm Setpoints 207
Three Position Step Control Algorithm 209
Contents

Setting a Failsafe Output Value for Restart After a Power Loss 210
Setting Failsafe Mode 211
Setpoint Rate/Ramp/Program 212
Setpoint Rate 213
Setpoint Ramp 214
Setpoint Ramp/Soak Programming 216
Chapter 6 - Input Calibration 226
Overview 227
Minimum and Maximum Range Values 228
Preliminary Information 230
Input 1 or 2 Set Up Wiring 232
Thermocouple Inputs using a Millivolt Source 232
RTD Inputs 232
Millivolts, Volts or Thermocouple Differential Inputs 233
Milliamperes 234
Input 1 or 2 Calibration Procedure 234
Restore Input Factory Calibration 238
Chapter 7 - Output Calibration 240
Overview 241
Current Output Calibration 241
Auxiliary Output Calibration 244
Position Proportional and Three Position Step Output Calibration 246
Restore Output Factory Calibration 250
Chapter 8 - Troubleshooting/Service 253
Overview 254
Troubleshooting Aids 255
Power-up Tests 256
Status Tests 257
6
Contents

7
Background Tests and Diagnostic 258
Controller Failure Symptoms 263
Troubleshooting Procedures 264
Procedure #1 265
Procedure #2 265
Procedure #3 266
Procedure #4 267
Procedure #5 268
Procedure #6 269
Procedure #7 271
Procedure #8 271
Procedure #9 272
Procedure #10 273
Restoring Factory Configuration 274
Chapter 9 - Parts List 276
Exploded View 276
Removing the chassis 281
Chapter 10 - Configuration via Honeywell EasySet 282
Communications Setup 283
Upload 288
Offline Configuration 290
Download 293
Online Configuration 294
Maintenance Data 298
About EasySet 301
Firmware update through Easyset App 302
Transfer configuration from the legacy device to the UDC2800 306
Contents

Chapter 11 - Modbus RTU Function Codes 20&21 314
General Information 314
Function Code 20 (14h) - Read Configuration Reference Data 317
Request and Response Formats 317
Byte Count 317
Data Byte Count 317
Reference Type Definitions 318
File Number 318
Register Address 318
Read Configuration Examples 318
Function Code 21 (15h) - Write Configuration Reference Data 320
Write Restrictions 320
Request and Response Formats 320
Reference Type Definitions 321
File Number 321
Register Address 321
Unrestricted Registers 322
Restrictions on Parameter Numbers in One Message 322
Write Configuration Examples 322
Modbus Read, Write and Override Parameters 323
General Information 323
Reading Control Data 324
Read Software Options Status 325
Miscellaneous Read Onlys 326
Setpoints 327
Using a Computer Setpoint (Overriding Controller Setpoint) 328
Configuration Parameters 330
Chapter 12 - Standard Modbus Read, Write and Override Parameters 374
Modbus RTU Message Format 375
8
Contents

9
Modbus RTU Function Codes 375
Digital Output Register Map 377
Digital Input Register Map 378
Loop Value Integer Register Map 378
Loop Value Register Map 386
Analog Input Register Map 391
Math, Calculated Value, or Variable Register Map 392
Math or Calculated Value Status Register Map 392
Shed Timer Reset Register Map 392
Alarm Status Register Map 393
Alarm Set Point Value Register Map 393
Set Point Program Value Register Map 394
SP Program 2 395
SP Program 3 397
SP Program 4 399
SP Program 5 400
SP Program 6 402
SP Program 7 404
SP Program 8 406
Set Point Program Additional Values Register Map 407
SP Program 2 409
SP Program 3 411
SP Program 4 413
SP Program 5 415
SP Program 6 417
SP Program 7 419
SP Program 8 420
Set Point Program Segment Map 422
Contents

Segment Register Map 425
Example for Determining a Segment Register 426
Chapter 13 - Modbus Communication Exception Codes 427
Introduction 427
Query 428
Response 428
Chapter 14 - Ethernet TCP/IP 429
Notices 431
10
Contents

CHAPTER
1ABOUT THIS GUIDE
Abstract
This document provides descriptions and procedures for the
Installation, Configuration, Operation, and Troubleshooting of your
controller.
Revision history
Revision Date Document
ID Description
1.0 November
2020
51-52-25-
157
Initial release of this document
2.0 December
2020
51-52-25-
157
Added maximum digits for PV and SP display
3.0 March
2021
51-52-25-
157
Implemented Modbus function
4.0 March
2021
51-52-25-
157
Added TPSC, PP and Slidewire
5.0 June 2022 51-52-25-
157
Added firmware upgrade via BLE app and PIE
tool configuration
Special Terms
The following table lists those symbols used in this document to
denote certain conditions.
Symbol Definition
PID Proportion Integration Differentiation
PIE Process Instrument Explorer
PV Process Variable
RTD Resistance Temperature Detector
11

Symbol Definition
SP Setpoint
SPDT Single-Pole Double-Throw
SPDT Single-Pole Single-Throw
TC Thermocouple
TFT Thin Film Transistor
TPSC Three Position Step Control
UDC Universal Digital Controller
References
The following list identifies all documents that may be sources of
reference for material discussed in this publication.
nHow to Apply Digital Instrumentation in Severe Electrical Noise
Environments: 51-52-05-01
12
Chapter 1 - About this guide

CHAPTER
2INTRODUCTION
Overview
Function
UDC2800 is a microprocessor-based stand-alone controller. It a high
degree of functionality and operating simplicity in a 1/4 DIN size
controller. This instrument is an ideal controller for regulating
temperature and other process variables in numerous heating and
cooling applications.
UDC2800 monitors and controls temperatures and other variables in
applications for industrial process control.
Features
n2 Universal Analog Inputs
n0.15% Accuracy
nFast scanning rate (100ms)
nUp to 4 Output Types
n2 Digital Inputs
nMath Functions
nEthernet and Modbus communication
nBluetooth configuration on mobile device
nNEMA4X and IP66 front face protection
NEMA and IP are certified by CSA.
n¼ DIN Size
nJumper free configuration
13

Easy to read displays
Bright display with prompts in English make the operator interface
easy to read, understand, and operate. Simple keystrokes let you set
operating parameters that meet your process control needs.
Analog Inputs
UDC2800 has two analog inputs with a typical accuracy of ±0.15% of
full-scale input and a typical resolution of 16 bits. Both analog inputs
are sampled ten times per second (every 100 ms).
The first, or Process Variable input, can be one of the various
thermocouple, RTD or linear actuations. Linear actuations have
thermocouple and RTD transmitter characterization capability as a
standard feature. Linear actuations also have square root capability.
The optional second input is isolated and accepts the same
actuations as input one, or it provides the Slidewire input for Position
Proportional control.
All actuations and characterizations are keyboard configurable. Cold
junction compensation is provided for thermocouple type inputs.
Upscale, downscale or failsafe sensor break protection is keyboard
configurable. A configurable digital filter of 0 to 120 seconds
provides input signal damping.
Thermocouple Health - In addition to the standard configurable
upscale, downscale or failsafe output burnout selections, the
condition of the thermocouple can be monitored to determine if it is
good, failing or in danger of imminent failure.
14
Chapter 2 - Introduction

15
Math Function
Algorithm—A pre-configured algorithm is available for easy
implementation. This includes the capability of using a Ratio and
Bias with any input. You can select from the following menu:
nFeedforward Summer—Uses either input, followed by a Ratio/Bias
calculation, summed directly with the computed PID output value
to provide a resultant output to the final control element
(standard feature).
nWeighted Average —Computes the weighted average of a PV or SP
for the control algorithm from two inputs (standard feature).
nFeedforward Multiplier—Uses any input, multiplied by the
calculated PID output to provide a resultant output which is sent
to the final control element (standard feature).
nSummer/Subtractor—Will add or subtract inputs with the result
used as the derived PV.
nMultiplier/Divider—Uses the analog inputs to calculate a derived
PV. Available with or without Square Root.
nInput High/Low Select—Specifies the PV input as the higher or
lower of the two inputs.
Digital Inputs
Two¹ isolated digital inputs are provided for remote dry contact
closure to select one of the following actions.
Note 1: The second Current Output and the second Digital Input are
mutually exclusive. Selection is made via a keyboard entry.
nManual control mode
nLocal setpoint 1, 2, 3, 4
nDirect controller action
nHold SP Ramp/Program
nSelect PID set 2, 3
nPV = Input2
nReRun - SP Ramp/Program
nRun - SP Ramp/Program
nExternal program reset
Chapter 2 - Introduction

nDisable PID integral action
nManual mode, failsafe output
nDisable keyboard
nOutput 1 = Fixed value
nStart Timer
nAuto/Manual Station
nInitiate Tuning
nInitiate PV Hot Start
nOutput 1 tracks Input 2
nTo Remote Setpoint
nPID reset feedback via Input 2
nTo Purge
nLow Fire
nPurge AUX
nTo Latching Manual Mode
nPV Hold
Also, the digital inputs can allow one of the following selections to be
combined with one of the above selections.
nSelect PID set 2
nDirect controller action
nLocal setpoint 1, 2, 3, 4
nDisable Accutune
nTo Run - SP Ramp/Program
Outputs
Output Types - UDC2800 may have up to four outputs made up of the
following output types:
nCurrent Outputs (4-20 or 0-20 mA)
nElectromechanical Relays (5 amps)
nDual Electromechanical Relays (2 amps)
nOpen Collector Outputs (Transmitter Power)
16
Chapter 2 - Introduction

17
Alarms
One or two electromechanical alarm relays are available to activate
external equipment when preset alarm setpoints are reached. Each of
the two alarms can be set to monitor two independent setpoints.
Each alarm setpoint can be either high or low alarm. The alarm type
can be selected to be either of the inputs, the Process Variable,
Deviation, Output, Shed from communications, PV rate of change, or
to alarm on manual mode activation or a Current Output Open
failure. It can also be used as an On or Off event at the beginning or
end of a Ramp/Soak segment. The alarm hysteresis is configurable
from 0 to 100% of range.
nAlarms can be configured as latching or non-latching.
nAlarm blocking is also available which allows start-up without
alarm energized until after it first reaches the operating region.
nPV rate of change alarm.
nLoop break alarm.
nTimer output reset.
nDiagnostic Alarm
Communications
A communications link is provided between UDC2800 and a host
computer or PLC via the RS485 Modbus® RTU (optional) or Ethernet
TCP/IP (optional) communications option. A Bluetooth
communication link is also available allowing a non-intrusive
configuration of the instrument.
Chapter 2 - Introduction

Miscellaneous Features
Auxiliary Output*(optional): Either or both of the two current outputs
can function as an Auxiliary Output which can be scaled from 0-20
mA or 4-20 mA for 0 to 100% for any range. It can be configured to
represent Input 1, Input 2, PV, active Setpoint, Local SP1, Deviation,
or the Control Output.
Transmitter Power: This output provides up to 28 volts DC to power a
2-wire transmitter (it requires the use of Open Collector Output
(Transmitter Power Output) selection or the Auxiliary Output).
Four Local and one Remote Setpoints: Can be configured to provide four
Local and one Remote Setpoints, which are selectable either via the
keyboard or by Digital Input.
Universal Switching Power: Operates on any line voltage from 90 to 264
Vac 50/60 Hz without jumpers. 24 Vac/dc instrument power,
powered by a power supply which provides double/reinforce
insulation or Safety Extra-low Voltage Circuit (SELV) Input, is
available as an option.
Timer: This standard feature provides a configurable time period of 0
to 99 hours, 59 minutes or units of minutes and seconds. It can be
started via the keyboard, alarm 2, or by a digital input. The timer
output is Alarm 1, which energizes at the end of the Timer Period.
Alarm 1 can be automatically reset. The Timer Period can be changed
between each batch. Status is shown on the lower display.
Moisture Protection: The NEMA4X and IP66 rated front face permits
use in applications where it may be subjected to moisture, dust, or
hose-down conditions.
Setpoint Ramp/Soak Programming (Optional): Enables you to use 8
programs and store 4 Ramp and 4 Soak segments per program.
Program can be linked up to 64 segments. Run or Hold of program is
keyboard or remote digital switch selectable.
Setpoint Rate: Lets you define a ramp rate to be applied to any local
setpoint change. A separate upscale or downscale rate is
configurable. A single setpoint ramp is also available as an
alternative.
CE Mark: Conformity with Radio Equipment Directive 2014/53/EU.
Radio Compliance information:
Federal Communications Commission (FCC) contains FCC ID:
2AVFQ-MCUDISP;
Industry Canada (IC) contains IC: 25762-MCUDISP.
18
Chapter 2 - Introduction

19
Approval Body Options:
CE, FCC, IC (Standard);
UL Listed (Optional): UL61010-1, 3rd Edition. UL61010-2-201, 2nd
Edition;
CSA Certified (Optional): CAN/CSA-C22.2 No. 61010-1-12+AMD1
Four Sets of Tuning Constants - Four sets of PID parameters can be
configured for each loop and automatically or keyboard selected.
Data Security: Five levels of keyboard security protect tuning,
configuration, and calibration data, accessed by a configurable 4-
digit code. Nonvolatile EEPROM memory assures data integrity
during loss of power.
Diagnostic/Failsafe Outputs: Continuous diagnostic routines detect
failure modes, trigger a failsafe output value and identify the failure
to minimize troubleshooting time.
High Noise Immunity: The controller is designed to provide reliable,
error-free performance in industrial environments that often affect
highly noise-sensitive digital equipment.
Accutune III™: This standard feature provides a truly plug and play
tuning algorithm, which will, at the touch of a button or through a
digital input, accurately identify and tune any process including
those with deadtime and integrating processes. This speeds up and
simplifies start-up plus allows retuning at any setpoint. The
algorithm used is an improved version of the Accutune IITM
algorithm found on earlier controllers. Two possibilities are now
offered when tuning your process: Fast Tune and Slow Tune.
Fast Tune: will tune the process in such a way that the temp is
reached faster, a slight overshoot will be allowed.
Slow Tune: will minimize overshoot, but it will take more time for the
process temperature to reach the target setpoint.
Heat/Cool (Duplex Tune): will automatically tune both the heating and
cooling sides of the process.
Fuzzy Logic: This standard feature uses fuzzy logic to suppress
process variable overshoot due to SP changes or externally induced
process disturbances. It operates independently from Accutune III
tuning. It does not change the PID constants, but temporarily
modifies the internal controller response to suppress overshoot. This
allows more aggressive tuning to co-exist with smooth PV response.
It can be enabled or disabled depending on the application or the
control criteria.
Chapter 2 - Introduction

Operator Interface
Function of Displays
Figure 2-1: Function of Displays
Table 2-1: Function of Displays
Item Description
1 Upper display shows Process Variable value (maximum 10 digits including
decimal point, eg. -XXXX.X). Its unit can be F, C or none.
2 Middle display shows working Setpoint and its value (maximum 10 digits
including decimal point, eg. -XXXX.X).
SP = Local Setpoint 1
2SP = Local Setpoint 2
3SP = Local Setpoint 3
4SP = Local Setpoint 4
RSP = Remote Setpoint
3 Bar display shows Process Variable, Setpoint and Output from top to bottom in
20
Chapter 2 - Introduction