Honeywell UDC3200 series User manual

UDC3200
Universal Digital Controller
Operator Manual
51-52-25-143
April 2008

4/08 UDC3200 Universal Digital Controller Operator Manual ii
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
Honeywell Organization WWW Address (URL)
Corporate http://www.honeywell.com
Honeywell Process Solutions http://hpswebhoneywell.com
Telephone
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/
UDC3200 is a U.S. registered trademark of Honeywell
Other brand or product names are trademarks of their respective owners.

4/08 UDC3200 Universal Digital Controller Operator Manual iii
Symbol Definitions
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.

4/08 UDC3200 Universal Digital Controller Operator Manual iv
Contents
1 INTRODUCTION ...................................................................................................1
2 INSTALLATION.....................................................................................................5
3 CONFIGURATION...............................................................................................24
4 MONITORING AND OPERATING THE CONTROLLER.....................................65

v UDC3200 Universal Digital Controller Operator Manual 4/08
5 TROUBLESHOOTING/SERVICE........................................................................79
6 SALES AND SERVICE........................................................................................82

04/08 UDC3200 Universal Digital Controller Operator Manual 1
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
32003200 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)
OUTOUT Indicates Control Relay 1 and/or
2 on.
SPSP During normal operation, the lower display
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).
FF
Or
CC
Indicates either degrees
Fahrenheit or Centigrade.
ALMALM Indicates Alarm 1 and/or Alarm 2 conditions
exist. MANMAN
Or
AA
Indicates either Manual or Auto
mode.
DIDI Indicates Digital Input 1 and/or 2 on. SPSP Indicates Local Setpoint #1.
Also, a bar is lighted when the
setpoint being used is shown on
the lower display.

2 UDC3200 Universal Digital Controller Operator Manual 04/08
Keys and Functions
FunctionFunctionFunction Selects functions within each
configuration group. Man
Auto
Man
Auto
Man
Auto
Selects Manual or Auto mode.
SetupSetup Scrolls through the configuration
groups. SP
Select
SP
Select
SP
Select
Hold key down to cycle through
configured setpoints.
Lower
Display
Lower
Display
Lower
Display
Returns Controller to normal display
from Set Up mode. Toggles various
operating parameters for display.
Run
Hold
Run
Hold
Run
Hold
Enables Run/Hold of the SP
Ramp or Program plus Timer
start.
Increases setpoint or output value.
Increases the configuration values or
changes functions in Configuration
mode groups.
Decreases setpoint or output
value. Decreases the
configuration values or changes
functions in Configuration mode
groups.
Infrared transceiver NEMA4X and IP66 screw
attachment (each corner)
1.3 CE Conformity (Europe)
73/23/EEC
89/336/EEC
Product Classification:
Enclosure Rating:
Installation Category (Overvoltage Category):
Pollution Degree:
EMC Classification:
Method of EMC Assessment:
Declaration of Conformity:
EMC

04/08 UDC3200 Universal Digital Controller Operator Manual 3
ATTENTION
WARNING

04/08 UDC3200 Universal Digital Controller Operator Manual 5
2 Installation
2.1 Pre-installation Information
2.2 Model Number Interpretation
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
_
_
_
IIIII IV
_
_
V
_
_ _
_
VI
KEY NUMBER - UDC3200 Single Loop Controller
Selection
Digital Controller for use with 90 to 264Vac Power DC3200
Digital Controller for use with 24Vac/dc Power DC3201
TABLE I - Specify Control Output and/or Alarms
TABLE II - Communications and Software Selections
0 _ _ _
1 _ _ _
2 _ _ _
3 _ _ _
_ 0 _ _
_ A _ _
_ B _ _
_ C _ _
No Selection _ _ 0 _
_ _ _ R
C _
E _
Math Option
Set Point Programming (1 Program, 12 Segments)
Set Point Programming Plus Math
Current Output (4 to 20ma, 0 to 20 ma)
T _
R _
_ E
_ A
No Additional Outputs or Alarms
Output #1
Software Selections
Standard Functions, Includes Accutune
Open Collector Plus Alarm 1 (5 Amp Form C Relay) _ T
Output #2 and Alarm
#1 or Alarms 1 and 2
_ B
One Alarm Relay Only
Availability
Infrared Interface Included (Can be used with a Pocket PC)
_ 0
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)
Electro Mechanical Relay (5 Amp Form C)
Solid State Relay (1 Amp)
None
A _
Description
Infrared interface
Reserved
Open Collector transistor output
Dual 2 Amp Relays (Both are Form A) (Heat/Cool Applications)
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
TABLE III - Input 1 can be changed in the field using external resistors
1 _ _
2 _ _
3 _ _
Carbon, Oxygen or Dewpoint (Requires Input 2) 1 6 0
_ 00
_ 10
_ 20
Slidewire Input (Requires two Relay Outputs) _ 40
None
TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA
TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA
TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA, 0-10V
Input 1
Input 2
TC, RTD, mV, 0-5V, 1-5V
TC, RTD, mV, 0-5V, 1-5V, 0-20mA, 4-20mA, 0-10V

6 UDC3200 Universal Digital Controller Operator Manual 04/08
TABLE IV - Options
0 _ _ _ _
1 _ _ _ _
_ 0 _ _ _
_ T _ _ _
_ S _ _ _
_ _ 0 _ _
_ _ _ 0 _
_ _ _ _ 0
TABLE V - Product Manuals
Product Information on CD - All Languages 0 _
English Manual E _
French Manual F _
German Manual G _
Italian Manual I _
Spanish Manual S _
_ 0
_ C
TABLE VI
None 0 _
Linen Customer ID Tag - 3 lines w/22 characters/line
Certificate of Conformance (F3391)
Certificate
None
None
None
Stainless Steel Customer ID Tag - 3 lines w/22 characters/line
Approvals CE (Standard)
No Selection
Manuals
Tags
None
None
CE, UL and CSA
Future Options
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
Wiring
Control Relay
Contact
Output #1 or #2
Indicator Status
N.O. Open
Off
N.C. Closed Off
Open Off N.O.
Closed On
Closed Off
On
N.C.
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
Variable NOT in Alarm State Variable in Alarm State Unit
Power
Alarm Relay
Wiring Relay
Contact
Indicators Relay
Contact
Indicators
N.O. Open Open
Off
N.C. Closed
Off
Closed
Off
N.O. Closed Open
On
N.C. Open
Off
Closed
On

04/08 UDC3200 Universal Digital Controller Operator Manual 7
2.4 Mounting
Physical Considerations
Overall Dimensions
Max. panel thickness
19,1
.75
Panel
Cutout
92,0 + 0,8
- 0,00
3,62 + 0,03
-0,00
92,0 + 0,8
- 0,00
3,62 + 0,03
-0,00
mm
inches
17,9
0,70
113,1
4,45
90,6
3,57 108,6
4,28
9,0
0,35
Figure 2-2 Mounting Dimensions (not to scale)

8 UDC3200 Universal Digital Controller Operator Manual 04/08
Mounting Method
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).
Attach screws and
washers here for
water protection
Mounting clips

04/08 UDC3200 Universal Digital Controller Operator Manual 9
2.5 Wiring
2.5.1 Electrical Considerations
Line voltage wiring
Mains Power Supply
within easy reach
of the OPERATOR
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.
Controller Grounding
Control/Alarm Circuit Wiring
Electrical Noise Precautions

10 UDC3200 Universal Digital Controller Operator Manual 04/08
Separate External Wiring
Use Suppression Devices
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
2 Analog 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
2.6 Wiring Diagrams
Universal Output Functionality and Restrictions
Table 2-5 Universal Output Functionality and Restrictions

04/08 UDC3200 Universal Digital Controller Operator Manual 11
Function of Other Outputs Output Algorithm
Type
Output 1/2
Option
Function of
Output 1/2 Output #3 Output #4 Auxiliary Output
Single Relay Output 1 Alarm 2 Alarm 1 Not Needed
Current Output INU Output 1 Alarm 1 Not Needed
Time Simplex
Dual Relay Output 1 Alarm 2 Alarm 1 Not Needed
Single Relay Output 1 Output 2 Alarm 1 Not Needed
Current Output INU Output 2 Output 1 Not Needed
Time Duplex or
TPSC or Position
Proportional Dual Relay Outputs 1 and
2
Alarm 2 Alarm 1 Not Needed
Single Relay INU Alarm 2 Alarm 1 Output 1
Current Output Output 1 Alarm 2 Alarm 1 Not Needed
Current Simplex
Dual Relay INU Alarm 2 Alarm 1 Output 1
Single Relay INU Alarm 2 Alarm 1 Outputs 1 and 2
Current Output Outputs 1 and
2
Alarm 2 Alarm 1 Not Needed
Current Dup. 100%
Current = COOL
and HEAT
Dual Relay INU Alarm 2 Alarm 1 Outputs 1 and 2
Single Relay N/A N/A N/A N/A
Current Output Output 1 Alarm 2 Alarm 1 Output 2
Current Duplex
50%
Current = HEAT
Aux Out = COOL Dual Relay N/A N/A N/A N/A
Single Relay * Output 1 Output 2 Alarm 1 Output 2
Current Output Output 2 Output 2 Alarm 1 Not Needed
Current/Time
Current = COOL
Time = HEAT Dual Relay * Outputs 1 & 2 Alarm 2 Alarm 1 Output 2
Single Relay * Output 1 Output 2 Alarm 1 Output 1
Current Output Output 1 Output 2 Alarm 1 Not Needed
Time/Current
Time = COOL
Current = HEAT Dual Relay * Outputs 1 & 2 Alarm 2 Alarm 1 Output 1

12 UDC3200 Universal Digital Controller Operator Manual 04/08
Wiring the Controller
L1
L2/N
4
5
6
7
1
10
11
12
13
14
15
16
17
7
8
9
20
21
22
23
24
25
26
27
18
19
See table for callout details
2
3
4
5
6
8
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.

04/08 UDC3200 Universal Digital Controller Operator Manual 13
4
5
6
7
8
9
10
11
12
13
14
15
16
17
L1
L2/N
22
23
24
25
26
27
Earth
Ground
Hot
Neutral
AC/DC
Line
Voltage
1
2
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 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.
1
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.
18
19
20
21
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.
3
2
3
Figure 2-5 Mains Power Supply

14 UDC3200 Universal Digital Controller Operator Manual 04/08
25
26
27
Use Thermocouple
extension wire only
Thermocouple RTD Millivolt or Volts
except 0-10 Volts
source
0-10 Volts Milliamps
–
+
+
R
–
1
2
3
–
0–10
Volt
source
+100K
100K Power
Supply
–+
Xmitter
+
–
250
25
26
27
+
R
–
25
26
27
+
R
–
25
26
27
+
R
–
1
25
26
27
+
R
–
1
Input #1
mV or
Volt
source
25
26
27
Use Thermocouple
extension wire only
+
R
–
Thermocouple Differential
+
+
–
–
The 250 ohm resistor for milliamp inputs or the voltage divider for 0-10 Volt inputs are supplied
with the controller when those inputs are specified. These items must be installed prior to start
up when the controller is wired. For 0-20 mA applications, the resistor should be located at the
transmitter terminals if Burnout detection is desired.
1
2
Splice and tape this junction between the two thermocouples. This junction may be located
anywhere between the thermocouples and the instrument terminals, it does not need to be close
to the other thermocouple junctions. Both thermocouples must be of the same type. For best
accuracy, the two thermocouples should be matched or, preferably, made from the same batch
of wire.
2
This controller does not produce a steady current for burnout detection. For that reason, when a
thermocouple is used in parallel with another instrument, it may be desirable to configure the
burnout selection for this controller to “NOFS” and use the burnout current from the other
instrument to also drive this controller.
3
3
4
The millivolt values for the Thermocouple Differential Input are for a pair of J thermocouples at
an ambient temperature mean of 450°F / 232°C.
4
Figure 2-6 Input 1 Connections