Home

Product Manual - Interstate Industrial Instrumentation Inc.

image

Contents

1. The Limit Controller CANNOT protect against a failure of the Control relay The Limit Controller CAN protect against a failure of the Control relay PROCESS LIMIT PROCESS LIMIT CONTROLLER CONTROLLER CONTROLLER CONTROLLER Lt AH AH POWER POWER CONTROL b CONTROL 1 e RELAY 1 2 RELAY SOLENOID SOLENOID POWER POWER LOAD LOAD Figure 2 15 Limit Controller Application Diagram 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 25 Configuration 3 Configuration 3 1 Overview Introduction Configuration is a dedicated operation where you use straightforward keystroke sequences to select and establish configure pertinent control data best suited for your application To assist you in the configuration process there are prompts that appear in the upper and lower displays These prompts let you know what group of configuration data Set Up prompts you are working with and also the specific parameters Function prompts associated with each group Table 3 1 shows an overview of the prompt hierarchy as it appears in the controller What s in this section The following topics are covered in this section Table 3 1 Configuration Topics 3 8 Communications Set Up Group 3 9 Alarms Set Up Group 3 10 Display Set Up Group 3 11 P I E Tool Ethernet and Email Configuration Screens 26 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Configuration
2. 130 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Resistance Thermometer Device 72 Restore Input Factory Calibration 79 Restore Output Factory Calibration 85 RS422 485 Modbus RTU Comm Interface 9 RTD Inputs 74 S Security Code 50 Security Code Entry 51 Set Up Group 27 Set Up Wiring Procedure For Auxiliary Output 84 Shed Enable 121 Shed Enable 38 Shed Time 37 Shed Time 121 Shed Time 38 Software Type 115 116 117 Software Version 115 117 Software Version Number 89 Solid State Relay Output 21 Specifications 8 Status Data 62 Status Tests 90 Stray Rejection 8 Suppression Devices 17 T T C Source 72 Temperature Units 43 Test Failures 90 Thermocouple Failing 39 Index Thermocouple Inputs Using A Thermocouple Source 74 Thermocouple Inputs Using An Ice Bath 73 Thermocouple Warning 39 Timing Out From Lower Display 52 Transmit Delay 121 Transmitter Characterization 32 Troubleshooting Aids 88 Troubleshooting Procedures 94 Troubleshooting Service 87 TX Delay 38 U UDC2500 Limit Controllers 1 Vv Vibration 10 Viewing The Operating Parameters 52 Voltage And Resistance Equivalents For 0 And 100 Range Values 70 W X Y Z Weight 10 Wiring 16 Wiring Bundling 17 Wiring Connections For Calibrating Auxiliary Output 84 Wiring Connections For Radiamatic Milliampere Millivolts Or Volts Except 0 To 10 Volts 75 77 Wiring Con
3. 004F 79 INT R W 0 No Shed 1 255 sample periods OOAl 161 INT R W 0 Percent 1 Engineering Units UDC2500 Universal Digital Limit ControllerProduct Manual 121 Modbus Read Write and Override Parameters plus Exception Codes 10 4 6 Alarms Table 10 8 lists all the register addresses and ranges or selections for the function parameters in Set up Group Alarms Table 10 8 Set up Group Alarms Parameter Register Description Address Hex Decimal Alarm 1 Setpoint 1 008C Type 140 Data Type INT Access Data Range or Enumerated Selection 0 None 1 Not Used 2 Not Used 3 PV 4 Deviation 5 Not Used 6 Alarm on Shed 7 Not Used 8 Not Used 9 Not Used 10 T C Warning 11 Failsafe or T C Fail 12 PV Rate of Change 13 Alarm on Digital Input Alarm 1 Setpoint 1 0009 Value 009 FP Within the range of selected parameter or PV span for deviation alarm Alarm 1 Setpoint 2 008E 142 INT Same as 140 Alarm 1 Setpoint 2 000A 010 FP R W Within the range of selected parameter or PV span for deviation alarm Alarm 2 Setpoint 1 0090 Type 144 INT Same as 140 Alarm 2 Setpoint 1 OOOB Value O11 FP R W Within the range of selected parameter or PV span for deviation alarm Alarm 2 Setpoint 2 0092 146 INT Same as 140 Alarm 2 Setpoi
4. Please wait Upload is in Progress Abort Figure 4 12 Configuration Upload in Progress Once the upload is complete click on the Ethernet amp Email Group Configure your Ethernet and Email parameters per Section 3 11 Once you have changed the Ethernet settings and downloaded them to your controller you will no longer be able to communicate with it until you change the IP address in the P LE Tool to be per the controller s new IP Address You will also need to re configure the Local Area Network LAN settings on your PC back to their original settings On some PCs and LANs it is possible to simply allow the PC to get these settings automatically via the DHCP server Contact your Information Technologies IT representative to see if this is available on your PC 68 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Input Calibration 5 Input Calibration A WARNING SHOCK HAZARD INPUT CALIBRATION MAY REQUIRE ACCESS TO HAZARDOUS LIVE CIRCUITS AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT BEFORE CALIBRATION 5 1 Overview Introduction This section describes the field calibration procedures for Input 1 e All input actuations in every UDC2500 controller are fully factory calibrated and are ready for configuration by the user e Field Calibration can improve the accuracy of the Controller if necessary
5. 46 to 66 1 54 mV 4 62 mV Differential Radiamatic Type RH 0 to 3400 18 to 1871 0 00 mV 57 12 mV Type RI 0 to 9999 0 to 9999 0 00 mV 60 08 mV RTD Alpha 0 00385 per IEC 60751 1995 100 ohms 300 to 1200 184 t0649 25 202 ohms 329 289 ohms 100 ohms low 300 to 300 184 to149 25 202 ohms 156 910 ohms 200 ohms 300 to 1200 184 t0649 50 404 ohms 658 578 ohms 500 ohms 300 to 1200 184 t0649 126 012 ohms 1646 445 ohms Linear Milliamps 4to 20 mA 4 00 mA 20 00 mA 0 to 20 mA 0 00 mA 20 00 mA Millivolts Oto 10mV 0 00 mV 10 00 mV Oto 50 mV 0 00 mV 50 00 mV 0 to 100 mV 0 00 mV 100 00 mV Volts 1to 5 Volts 1 00 Volts 5 00 Volts Oto 5 Volts 0 00 Volts 5 00 Volts O to 10 Volts 0 00 Volts 10 00 Volts The Factory Calibrated millivolt values for the Thermocouple Differential Input are for a pair of J thermocouples at an ambient temperature mean of 450 F 232 C Other thermocouple types and ambient temperature means may be accomplished via Field Calibration of the input with the range value limits being 4 mV to 16 mV for the zero and span values See Table 5 7 for procedure The range values for Radiamatic Type RI are customer configurable 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 71 5 3 Preliminary Information Disconnect the Field Wiring Tag and disconnect any field wiring connected to the input terminals on the rear of the controller Input 1 Connections Figure 5 1 Input 1
6. To determine the appropriate diagrams for wiring your controller refer to the model number interpretation in this section The model number of the controller can be found on the outside of the case Wiring the Controller Using the information contained in the model number select the appropriate wiring diagrams from the composite wiring diagram below Refer to the individual diagrams listed to wire the controller according to your requirements Auxiliary Output and Digital Inputs Terminals See Figure 2 17 Limit Relay Terminals See Figures 2 8 through 2 14 AC Line Voltage Terminals See Figure 2 5 Outputs 3 and 4 Terminals See Figures 2 8 through 2 14 Input 1 Terminals See Figure 2 6 Communications Terminals See Figures 2 15 and 2 16 XXXX Figure 2 4 Composite Wiring Diagram 18 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 3 07 Installation 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 mm copper conductor is recommended Before powering the controller see Prelimnary Checks in this section of the Product Manual Git is the user s responsibility to provide a switch and non time delay
7. Tuning and Setpoint Ramp parameters are available for read only No other parameters can be viewed Lower Display LOCK or Until NONE is in the upper display til you see 2 Enter OUTPUT am En Upper Display SET or OPTIONS N A 7 de Setup Group Lower Display OPTION for the Auxiliary Output until you see Function Upper Display the current selection Lower Display ARANGE for the Auxiliary Output bh org to change the range configuration to the other selection 3 Scroll through Function until the lower display rolls through the rest of the functions and Functions Mf returns to Upper Display the new selection Lower Display ARANGE for the Auxiliary Output Aor to change the range selection in the upper display back to the proper selection You will see Upper Display Original range selection Lower Display ARANGE for the Auxiliary Output 4 Return to Normal to return to Normal operating mode Operation The factory calibration will be restored 86 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Troubleshooting Service 7 Troubleshooting Service 7 1 Overview Introduction Instrument performance can be adversely affected by installation and application problems as well as by hardware problems We recommend that you investigate the problems in the following order e installation related problems e application related problems e hardware and software related problems
8. UDC2500 Universal Digital Controller Limit Control Model Product Manual 51 52 25 136 March 2007 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 About This Document Abstract This document provides descriptions and procedures for the Installation Configuration Operation and Troubleshooting of your UDC2500 Controller 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 E Protective Earth PE terminal Provided for connection of the protective earth green or green yellow supply system conductor ip 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 Functio
9. and 105 FACTOR Use a value in engineering units to represent all AUX OUT parameters except output Use a value in percent for Output Output can be between 5 and 105 CRANGE AUXILIARY OUTPUT RANGE allows the user to easily select 4 20mA output or 0 20mA output operation without the need for recalibration of the instrument ATTENTION Changing the Auxiliary Output Range will result in the loss of Field Calibration values and will restore Factory Calibration values DIGIN1 DIGITAL INPUT 1 SELECTIONS AlI selections are available for Input 1 The controller returns to its original state when contact opens except when overruled by the keyboard EXTERNAL RESET DIGITAL INPUT resets the latching relay on contact closure DIS DIS Disable ENAB ENAB Enable 36 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Configuration 3 8 Communications Set Up Group Introduction The Communications group lets you configure the controller to be connected to a host computer via Modbus or Ethernet TCP IP protocol Introduction A controller with a communications option looks for messages from the host computer If these messages are not received within the configured shed time the controller will SHED from the communications link and return to stand alone operation You can also set the SHED output mode and setpoint recall and communication units Up to 99 addresses c
10. 51 Loop Data Alarm Details 60 Loop Data Digital Input Details 61 Loop Data Screen 58 Loopback 38 Low Limit Controller 1 Low Setpoint Limit 30 M Mains Power Supply 16 19 Mechanical Shock 10 Minimum And Maximum Range Values 70 Modbus 37 Modbus Read Write And Override Parameters 113 Modbus Rtu Function Codes 104 Model Number Interpretation 11 Monitoring Your Limit Controller 52 Mounting 14 Mounting Method 15 Mounting Procedure 15 N Non Volatile Memory Retention 113 O Open Collector Relay Output 22 Operating Principles 54 Operating The Limit Controller 49 Operating Your Limit Controller 54 Operator Interface 2 50 Options Set Up Group 35 Output Calibration 83 Override Parameters 114 P Q P LE Tool 64 P L E Tool Ethernet And Email Configuration Screens 45 DIE Tool Maintenance Screens 58 Parts Identification 102 Parts List 101 Permissible Wiring Bundling 17 Physical Considerations 14 Power Consumption 9 Power Failure Symptoms 95 Power Inrush Current 9 Power Line Frequency 43 Power Up 30 Power Up Logic 54 Power Up Tests 90 Pre Installation Information 8 Process Instrument Explorer 4 R Read Onlys 115 Reading Control Data 115 Register Address 107 111 Register Address Structure 105 Register Addresses 116 Register Count 105 Relative Humidity 10 Relay Contacts 57 Removing The Chassis 103 Reset The Latching Relay 56
11. Return MSB in Function Code byte set with Slave Device Failure 04 in the data field 02 83 04 CRC CRC Table 10 10 Modbus RTU Data Layer Status Exception Codes Exception Definition Description Code Illegal Function The message received is not an allowable action for the addressed device Illegal Data Address The address referenced in the function dependent data section of the message is not valid in the addressed device Illegal Data Value The value referenced at the addressed device location is no within range Slave Device Failure The addressed device has not been able to process a valid message due to a bad device state Slave Device Busy The addressed device has ejected a message due to a busy state Retry later 07 NAK The addressed device cannot process the current Negative Acknowledge message Issue a PROGRAM POLL to obtain device dependent error data Buffer Overflow The data to be returned for the requested number of registers is greater than the available buffer space Function Code 20 only 126 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Ethernet TCP IP 11 Ethernet TCP IP 11 1 Overview 3 07 Ethernet parameters can only be configured via the Process Instrument Explorer software Ethernet IP Address is 10 0 0 2 as shipped from the Factory The MAC address is printed on the case label of each instrument When constructing a network it is recommended that a Switch be used to co
12. and use the information presented in this section to solve them What s in this section The following topics are covered in this section 7 2 Troubleshooting Aids e Overall Error Messages e Controller Failure Symptoms e Customer Support e Determining the Software Version Number 13 Power up Tests 7 5 Background Tests 7 6 Controller Failure Symptoms 7 7 Troubleshooting Procedures e Power Failure e Alarm Relay Output Failure e Keyboard Failure ES DEES 7 8 Restore Factory Configuration Installation related problems Read the Installation section in this manual to make sure the UDC2500 has been properly installed The installation section provides information on protection against electrical 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 87 Troubleshooting Service noise connecting external equipment to the controller and shielding and routing external wiring ATTENTION System noise induced into the controller will result in diagnostic error messages recurring If the diagnostic error messages can be cleared it indicates a soft failure and is probably noise related If system noise is suspected completely isolate the controller from all field wiring Use calibration sources to simulate PV and check all controller functions i e Gain Rate Reset Output Alarms etc Application related problems Review the application of the controller then if necessary direct your questions to the loc
13. Information Limit Relay ATTENTION The Limit relay is designed to operate in a Failsafe mode This results in momentary 5 seconds maximum limit action when power is initially applied until the unit completes self diagnostics If power is lost to the unit the Limit Control Relay will still function Table 2 2 Limit Relay Contact Information Control Relay Rel 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 3 Alarm Relay Contact Information a en Tan Contact Contact ae ee 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 13 Installation 2 5 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 e Overall dimensions and panel cutout requirements for mounting the controller are shown in Figure 2 2 e 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 e The front panel is moisture rated NEMA3 and IP55 rated and can be easily u
14. Plus Auxiliary Output Digital Inputs 10 Base T Ethernet Modbus RTU Plus Auxiliary Output Digital Inputs Communications Software Selections Limit Controller Reserved No Selection None Infrared Interface Included Can be used with a Pocket PC Infrared interface Availability DC 2500 2501 TABLE Ill Input 1 can be changed in the field using external resistors Availability DC 2500 2501 TABLE IV Options CE UL and CSA Standard Approvals CE UL CSA and FM Tags None Stainless Steel Customer ID Tag 3 lines w 22 characters line Future Options Availability DC 2500 2501 TABLE V Product Manuals Product Information on CD All Languages English Manual 51 52 25 127 French Manual 51 52 25 127 FR Manyals German Manual 51 52 25 127 DE Italian Manual 51 52 25 127 IT Spanish Manual 51 52 25 127 SP Certificate None Certificate of Conformance F3391 continued UDC2500 Universal Digital Limit ControllerProduct Manual 11 Installation Limit Controller Restrictions Comments 1 FM approved units with communications are limited to read only 2 FM approved units are restricted to TC and RTD type inputs 3 UL listed for regulatory use only eg ET e ee EE c Ieput 2 Not Available with Limit Model Figure 2 1 Model Number Interpretation 12 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Installation 2 4 Limit and Alarm Relay Contact
15. Security and Lockout it is best to configure this group last after all the other configuration data has been loaded Function Prompts Table 3 4 LOCK Group Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition SECUR 0 to 4095 When LOCK is configured as NONE the Security Code number is displayed and can be changed using the raise lower keys NONE all parameters are read write CAL all parameters are read write except Calibration CONF configuration parameters are Read Only no writes permitted SP Only the Lockout group is available for read write Setpoint value is Read Only 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 29 Configuration 3 5 Limit Set Up Group Introduction This data deals with the type of Limit Control you want power up Logic setpoint high and low limits and the default display function Prompts Table 3 5 LIMIT Group Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition LOorHI LOW LOW Limit Control latching relay de energizes when PV goes below configured setpoint cannot be reset until PV rises above configured setpoint and M A RESET key is pressed HIGH HIGH Limit Control latching relay de energizes when PV goes above configured setpoint cannot be reset until PV drops below configured setpoint and M A RESET key is pressed POW
16. The local operator then has control of the output The controller is in Monitor Mode if the Shed timer is disabled UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Modbus Read Write and Override Parameters plus Exception Codes 10 2 Reading Control Data Overview The following control data can be read from this instrument e Input 1 Register Addresses Use the identifying codes listed in Table 10 1 to read the specific items A Write request for these codes will result in an Error message Table 10 1 Control Data Parameters Parameter Register Data Data Range or Description Address Type Enumerated Selection Input 1 7B 123 FP In Engineering Units or Percentage LSP1 27 30 FP R W In Engineering Units Within Set point Limits 10 3 Miscellaneous Read Onlys 10 3 1 Register Addresses for Read Onlys The identifying register addresses listed in Table 10 2 represent some information that is Read only No Writes allowed Table 10 2 Miscellaneous Read Onlys Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal Software Type 008B 139 INT RD READ only 38 UDC2500 Limit Software Version OOA7 167 INT RD READ only Value less than 255 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 115 Modbus Read Write and Override Parameters plus Exception Codes 10 4 Configuration Parameters Overview Listed on the
17. Troubleshooting Power Failure Symptoms Step What to do How to do it 1 Check the AC line voltage 2 Make sure the chassis plugs into the rear of the case properly 3 Check the system for Brown outs heavy load switching etc and conformance to installation instructions 4 Change Power board Use a voltmeter to measure the AC voltage across terminals L1 and L2 on the rear terminal panel of the controller Check the earth ground connection Withdraw the chassis and visually inspect the controller board and the inside of the case Refer to Section 2 Installation Installation instructions supplied with new board 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 95 Troubleshooting Service Procedure 2 Table 7 6 explains how to troubleshoot Latching Output Relay failure Table 7 6 Troubleshooting Latching Output Relay Failure Step What to do How to do it 1 Make sure all the configurable Refer to Section 3 Configuration to check all this data stored in the controller is data and how to reconfigure correct Reconfigure if necessary 2 Check that the Latching Relay Move the setpoint above or below the PV value actuates properly depending on the type of Limit Control configured Listen for the click of the relay as the setpoint is moved above or below the PV 3 Check the Latching Relay Refer to Section 2 4 Limit Control and Alarm Relay jumper position NO or NC Contact Information
18. Wiring Terminals Equipment Needed Table 5 2 lists the equipment you will need to calibrate the specific types of inputs that are listed in the table You will need a screwdriver to connect these devices to your controller Table 5 2 Equipment Needed Type of Input Equipment Needed Thermocouple e A calibrating device with at least 0 02 accuracy for use asa Inputs Ice Bath signal source such as a millivolt source e Thermocouple extension wire that corresponds with the type of thermocouple that will be used with the controller input e Two insulated copper leads for connecting the thermocouple extension wire from the ice baths to the mV source e Two containers of crushed ice Thermocouple e A calibrating device with at least 0 02 accuracy for use asa Inputs T C Source signal source such as a millivolt source e Thermocouple extension wire that corresponds with the type of thermocouple that will be used with controller input RTD Resistance e A decade box with at least 0 02 accuracy capable of providing Thermometer stepped resistance values over a minimum range of 0 to 1400 ohms Device with a resolution of 0 1 ohm e Three insulated copper leads of equal length for connecting the decade box to the controller Milliampere e A calibrating device with at least 0 02 accuracy for use as a Millivolt Volts and signal source Radiamatic e Two insulated copper leads for connecting the calibrator to the con
19. 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 e Separate External Wiring Separate connecting wires into bundles See Permissible Wiring Bundling Table 2 5 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 5 Permissible Wiring Bundling Bundle No J Wire Functions OE 1 e Line power wiring e Earth ground wiring e Line voltage control relay output wiring e Line voltage alarm wiring 2 Analog signal wire such as e Input signal wire thermocouple 4 to 20 mA etc e 4 20 mA output signal wiring Digital input signals 3 e Low voltage alarm relay output wiring e Low voltage wiring to solid state type control circuits e Low voltage wiring to open collector type control circuits 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 17 Installation 2 7 Wiring Diagrams Identify Your Wiring Requirements
20. for information to correct the failure Table 4 3 Error Messages L Promet Description EE FAIL Unable to write to nonvolatile memory IN1FL Two consecutive failures of input 1 integration CNFERR Configuration Errors Low limit greater than high limit for PV or SP INIRNG Input 1 Out of Range Out of range criteria Linear range 10 out of range Characterized range 1 out of range PV LIM PV Out of Range PV PV PV bias FAILSF Failsafe conditions for Failsafe are EEROM Test Failed Scratch Pad RAM Test Failed Configuration Test Failed Check the Status group TCWARN Thermocouple sensor is starting to burnout TCFAIL Thermocouple sensor is in imminent danger of burning out OUT2 FL Current Output 2 failure is less than 3 5 mA High and Low Limit Indication When the high or low limit is exceeded the lower display indicates the word LIMIT blinking The PV is indicated in the upper display This will continue until the Out of Limit condition exists and you reset the latching relay using the M A RESET key or through the Optional External Reset feature The Limit Relay cannot be reset while a Limit condition exists 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 53 Operating the Limit Controller 4 6 Operating Your Limit Controller Operating Principles The Limit Controller accepts signals from such sources as Thermocouples T Cs Resistance Temperature Detectors R
21. in Set up Group Display Table 10 9 Set up Group Display Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Decimal Point 009B 155 INT R W 0 XXXX Fixed Location 1 XXX X Floating decimal point to one 2 XX XX Floating decimal point to two Temperature 0081 129 INT R W 0 F Units i ae 2 None Power 00A6 166 INT R W 0 60 Hertz Frequency 1 50 Hertz Lower Display OOAE 174 INT R W 0 Enable 1 Disable TC Diagnostics O09F 159 INT R W 0 Enable 1 Disable 124 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Modbus Read Write and Override Parameters plus Exception Codes 10 5 Modbus RTU Exception Codes Introduction When a master device sends a query to a slave device it expects a normal response One of four possible events can occur from the master s query e Slave device receives the query without a communication error and can handle the query normally It returns a normal response e Slave does not receive the query due to a communication error No response is returned The master program will eventually process a time out condition for the query e Slave receives the query but detects a communication error parity LRC or CRC No response is returned The master program will eventually process a time out condition for the query e Slave receives the
22. on Abort button Device Type UDE3500 vi Upload Status Please wait Upload is in Progress wn Cancel Figure 4 9 Configuration Upload in Progress Once the upload is complete click on the Ethernet amp Email Group Configure your Ethernet and Email parameters per Section 3 11 Once you have changed the Ethernet settings and downloaded them to your controller you will be able to communicate with it via Ethernet 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 65 Operating the Limit Coniroller Configuring the Controller via Ethernet Communications 66 WARNING Configuring the Controller via Ethernet Communications requires that you change your PC s IP settings If you have never done this before then it is strongly recommended that you consult with your Information Technologies IT representative before proceeding First write down the current Local Area Network LAN configuration values for your PC for its IP Address Subnet Mask and Default Gateway settings Put these someplace where you can find them later Connecting to the Ethernet Port in the Controller requires that you have either an Ethernet crossover cable or a MDI compliant Switch or Hub available with a straight through cable The crossover cable can be used to directly connect your PC to the Controller while the Switch or Hub can be used to connect your PC and Controller to the Hub or Switch via straight
23. the Limit Coniroller Status Data Select Status Data from the Maintenance Data menu ee Maintenance Data Ethernet Status The Status Data screen lets you see the current status of the controller s diagnostics If the controller has detected a problem this screen will show the detected problem If the controller is equipped with the Real Time Clock Option then pressing the Diagnostics button will show the time and dates that the problem occurred and when it was cleared Maintenance Status Data Ve Screen refreshes automatically if the communication link is selected as RS485 or Ethernet Tool provides manual refresh if communication link is selected as Infrared RAM Inputi CFG Memory Input2 Cal Memory Input3 Fact Memory Input4 NotActive Fail Safe Inputs NotActive Fail Safe2 TC Inp2 D TC Inpt TC Inp3 KO Device Type UpCem DA vi Diagnostics Figure 4 6 Status Data Maintenance Screen 62 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Operating the Limit Coniroller Ethernet Status Select Ethernet Status from the Maintenance Data menu Maintenance Data Loop Data Status Data This screen only appears in instruments that have the Ethernet Communications option Essentially this screen shows the same Ethernet diagnostic messages as available on the controller via the lower display window See Section 7 5 for det
24. the restore operation it automatically resets itself and restarts in the product mode The instrument configuration will now be the same as it was when the instrument left the factory and all user entered configurations since that time have been overwritten 100 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Parts List 8 Parts List 8 1 Exploded View Introduction Figure 8 1 is an exploded view of the UDC2500 Controller Each part is labeled with a key number The part numbers are listed by key number in Table 8 1 Parts not shown are listed in Table 8 2 Figure 8 1 UDC2500 Exploded View 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 101 Parts List Table 8 1 Parts Identification Key Part Number Description Number 51453143 501 Bezel Assembly and Bezel Gasket 51452758 502 Display Keyboard with IR 3 51452822 502 Power Output PWA 90 264 Vac Operation BJE Power Output PWA 24 Vac dc Operation 4 51452810 501 Auxiliary Output Digital Input RS 422 485 Communications PWA lee Auxiliary Output Digital Input Ethernet Communications PWA 51452801 504 MCU Inputs PWA with IR for Limit Controllers Output 1 30755306 501 e Electro Mechanical Relay 30756679 501 e Open Collector Output PWA 30756725 501 e Solid State Relay 51452759 501 Case Assembly including Mounting Kit with four brackets Alarm 2 30755306 501 e Electro Mechanical Relay 30756679 501 e Open Collector O
25. through cables Once you have made an Ethernet connection between your PC and the controller then change the Local Area Network LAN settings on your PC to be as follows IP Address 10 0 0 3 Subnet Mask 255 255 255 0 Default Gateway 10 0 0 1 Now open your P LE Tool program and select PC Comm Setup and select Ethernet as your Communication Type as shown in Figure 4 10 CommunicationT ype Ethernet v Select Type to setup PC Comm Setup gt Upload Figure 4 10 Ethernet Communications Type Selection UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 3 07 Operating the Limit Coniroller Now set your Ethernet address to 10 0 0 2 as shown in Figure 4 11 Communication Setup Ethernet ts Screen helps to setup Ethemet parameters r Ethernet Parameters IP Address Timeout 1 20 sec Retries Figure 4 11 Ethernet Communications Address Close the Ethernet configuration window and then single click on the Online Configuration button e i CELI Online Configuration UDC2500 Universal Digital Limit ControllerProduct Manual 67 Operating the Limit Coniroller Then click on the Start button The P LE Tool should start uploading the configuration information from the controller as shown in Figure 4 12 Online Configuration gt To terminate Upload click on Abort button Device Type ud C3500 v1 Upload Status Pn
26. which version of UDC2500 you have and help them determine a solution to your problem 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 89 Troubleshooting Service 7 3 Power up Tests What happens at power up When power is applied the controller will run three diagnostic tests After these tests are completed TEST DONE is displayed Test Failures If one or more of these tests fail the controller will go to the Failsafe Manual Mode and FAILSF will flash in the lower display and a message indicating which test failed will appear in the lower display Then DONE will appear in the lower display 7 4 Status Tests Introduction When required the results of these tests can be checked to determine the reason the controller has gone to Failsafe How to check the status tests The procedure in Table 7 2 tells you how to display the results of the status tests Table 7 2 Procedure for Displaying the Status Test Results el Om m mm ne setup Upper Display READ Lower Display STATUS Set Up Group a Ge 2 Read the test Function You will see results Nee Upper Display NO or YES YES indicates a failure Lower Display FAILSAFE Function Upper Display PASS or FAIL Noa Lower Display TEST 90 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 7 5 Background Tests Introduction Troubleshooting Service The UDC2500 performs ongoing background tests to verify data and me
27. 0 5V type that uses a dropping resistor the dropping resistor must be remotely located across the transmitter terminals Otherwise the input at the UDC terminals will always be 0 mA i e within the normal operating range when the 0 20 mA line is opened 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 33 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition 0 01 to 1 00 EMISSIVITY is a correction factor applied to the Radiamatic input signal that is the ratio of the actual energy emitted from the target to the energy which would be emitted if the target were a perfect radiator Available only for Radiamatic inputs 34 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Configuration 3 7 Options Set Up Group Introduction The Options group lets you configure the remote mode switch Digital Inputs to a specific contact closure response or configure the Auxiliary Output to be a specific selection with desired scaling Function Prompts Table 3 7 OPTION Group Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition AUXOUT AUXILIARY OUTPUT SELECTION This selection provides an mA output representing one of several control parameters The display for auxiliary output viewing will be in engineering units for all but output Output will be displayed in percent ATTENTION Other promp
28. 07 UDC2500 Universal Digital Limit ControllerProduct Manual 23 Installation Auxiliary Output Auxiliary Load 0 1000 Q Connect shield to ground at one end only Digital Inputs Digital Input 1 Connect shield to ground at one end only XXXX Figure 2 12 Auxiliary Output and Digital Inputs Option Connections OUTPUT 3 approximately 25 Vdc 2 Wire Transmitter If necessary install a zener diode here to reduce voltage at the transmitter A 1N4733 will reduce the voltage at the transmitter to Configure A2S1TY NONE A2S2TY NONE INPUT 1 XXXX Figure 2 13 Transmitter Power for 4 20 mA 2 wire Transmitter Using Open Collector Alarm 2 Output 24 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Installation 2 Wire Transmitter Configure AUXOUT OUT Auxiliary Output Calibration ZEROVAL 4095 SPANVAL 4095 AUXILIARY OUTPUT INPUT 1 XXXX If necessary install a zener diode here to reduce voltage at the transmitter A 1N4733 will reduce the voltage at the transmitter to approximately 25 Vdc Figure 2 14 Transmitter Power for 4 20 mA 2 Wire Transmitter Using Auxiliary Output 2 8 Limit Control Application Diagram Limit Controller Wiring Figure 2 15 shows the RIGHT and WRONG way to wire your Limit Controller
29. 24 Vac 24 1 20 to 27 20 to 27 Frequency Hz 50 0 2 49 to 51 48 to 52 For Vac 60 0 2 59 to 61 58 to 62 The maximum moisture rating only applies up to 40 C 104 F For higher temperatures the RH specification is derated to maintain constant moisture content 10 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Installation 2 3 Model Number Interpretation Introduction 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 3 07 KEY NUMBER UDC2500 Single Loop Controller Selection Availability Digital Controller for use with 90 to 264Vac Power DC2500 Digital Controller for use with 24Vac dc Power DC2501 D Availability DC 2500 2501 TABLE Specify Control Output and or Alarms Selection TE Electro Mechanical Relay 5 Amp Form C a Output 1 p Solid State Relay 1 Amp S Open Collector transistor output be No Additional Outputs or Alarms One Alarm Relay Only S 2 Al en and 2 EM Relay 5 Amp Form C Plus Alarm 1 5 Amp Form C Relay WE Solid State Relay 1 Amp Plus Alarm 1 5 Amp Form C Relay d Open Collector Plus Alarm 1 5 Amp Form C Relay a S Availability DC 2500 2501 TABLE II Communications and Software Selections None Auxiliary Output Digital Inputs 1 Aux and 1 DI or 2 Dl RS 485 Modbus
30. 3 High Range float high word NOT SUPPORTED High Range float low word NOT SUPPORTED 3 Value float low word NOT SUPPORTED 9 to 13 Description Text ASCII string NOT SUPPORTED Register Count The register count depends on the data format of the registers being read or written Integer data is represented in sixteen bits and is transferred high byte first Floating point data is transferred in IEEE 32 bit format The register count definitions are 0001 Integer Data 0002 Floating Point Data 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 105 Modbus RTU Function Codes 9 3 Function Code 20 14h Read Configuration Reference Data Description Function code 20 14 Hex is used in this instrument to read information stored in its configuration database Each configuration item is explicitly addressed by a file number and register address EEE 32 bit floating point and 16 bit integer formats are supported Request and Response Formats The Request and Response formats for Function code 20 14 Hex are shown below Details for each block reference follow Request Message Format Slave Function Byte Reference File Register Register Address Code 14 Count Type Number Address Count Dale Reference we Data Byte Type Data Data Data Data Count yp CRC CRC vee Data Data For Infrared Transactions add three BOFs COhex at the beginning of each message and one EOF FF
31. 3 2 Configuration Prompt Hierarchy Table 3 2 Configuration Prompt Hierarchy LOCK LIMIT oomi OPTIONS COND CAAD canes RENAE TEAD SDENAE erena Eao R ALARMS l gt msm msr msia msta amer ALARMT BLOCK DIAGAL DISPLY STATUS 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 27 Configuration 3 3 Configuration Procedure Introduction Each of the Set Up groups and their functions are pre configured at the factory The factory settings are shown in Section 3 12 If you want to change any of these selections or values follow the procedure in Table 3 3 This procedure tells you the keys to press to get to any Set Up group and any associated Function parameter prompt Procedure ATTENTION The prompting scrolls at a rate of 2 3 seconds when the SET UP or FUNCTION key is held in Also 4 or Ww keys will move group prompts forward or backward at a rate twice as fast Table 3 3 Configuration Procedure step Operation Press pen 1 Enter Set Up an Upper Display SET Mode NEE Lower Display LOCK This is the first Set Up Group title 2 Select any Set e Sequentially displays the other Set Up group titles shown in Up Group N Z the prompt hierarchy in Table 3 2 Configuration Prompt Hierarchy You can also use the or keys to scan the Set Up groups in both directions Stop at the Set Up group title that describes the group of parameters you want to configure Then proceed t
32. 37 INT RW 0 Normal Selections 1 Reset Limit Relay 00C4 196 INT IR 0 Not Latched Latched 1 Latched if in Limit Condition Set Point Max 0007 7 FP R W 0 to 100 of PV Engineering Units Set Point Min 0008 8 FP R W 0 to 100 of PV Engineering Units Display 00B1 177 INT R W 0 PV 1 Set Point 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 117 Modbus Read Write and Override Parameters plus Exception Codes 10 4 3 Input 1 Table 10 5 lists all the register addresses and ranges or selections for the function parameters in Set up Group Input 1 Table 10 5 Set up Group Input 1 Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Input 1 Type 009F 159 INT R W 1 BTC 2 ETCH 3 ETCL 4 JTCH 5 JTCM 6 JTCL 7 KTCH 8 KTCM 9 KTCL 10 NNMH 11 NNML 12 Nicrosil H TC 13 Nicrosil L TC 14 RTC 15 STC 16 TTCH 17 TTCL 183 WTCH 19 WTCL 20 100 PT RTD 21 100 PT LO RTD 22 200 PT RTD 23 500 PT RTD 24 Radiamatic RH 25 Radiamatic RI 26 0 20 mA 27 4 20 mA 28 0 10 mV 29 0 50 mV 30 100 mV 31 0 5 Vdc 32 1 5 Vdc 33 0 10 Vdc 34 Unused 35 Unused 36 Thermocouple Differential 37 PR40 PR20 Thermocouple ATTENTION Changing the Input Type will result in the loss of Field Calibration values and will restore the Factory Calibration values 118 UDC2500 Univer
33. 5 4 Input WSet Up Wirins 22 2ee li cake Said Ei aA ee a 73 9 5 Input 1 Calibration Procedure sei voteiiten dei 22 mn EAR 78 5 6 Restore Input Factory Calibration cece eseessecsseceeceseceseceseceseceseeeeeeseaeeeaeeeaeeeaaessaecsaecnaeenaeens 79 6 OUTPUT e ITM UU e D 83 Gel MON ELVIC Wee rar Rss el ae Ate Delete declaw Wes tht let 83 6 2 Auxiliary Output Calibration sx asus Eed Ae NEE ANEN SES dE 83 6 3 Restore Output Factory Calbraton eee ceecesceseesseeeeeeesseeeseesseecsaecaecaecssecsaeesseeeseeeseeseneeses 85 7 TROUBLESHOOTING SERVICE 6 avisssitaccicastascecsceecatcciacsactecsanaccteeceasscuceaasuancedons 87 TE RE 87 7 2 Troubleshooting Aids 2er 88 7 3 Bowerup E 90 TA Status Tests EE 90 19 2 Background Tests 21822 iii iin ede eaten ebb edt 91 7 6 Controller Failure Svmptoms sisest tisessa gest eiee r tase a ees EEEN eeen aa E E EEEa 93 ET Troubleshooting Proced resi 2 20 2 5082 ns ARE anal 94 7 8 Restoring Factory Configuration 20 0 0 ee eeceeseeseeeseecseeccecsseceaecesecesecsseceseesseeseaeeeaeseneeeneeeaaeenaes 100 8 PARTS E CH RE 101 8 1 Exploded View rare a aden NEEN 101 8 2 Removing th Chassis 00 eee en eee ie Rah eG eee ee Lewd ete 103 9 MODBUS RTU FUNCTION CODEG cccccsssseeeeeeseeeeeeeeesseneeeeensseneeeeenseeneeees 104 VDS EE 104 92 General Information 0as 2 sinn 104 9 3 Function Code 20 14h Read Configuration Reference Data 106 9 3 1 Read Configur
34. 500 Universal Digital Limit ControllerProduct Manual 3 07 Modbus Read Write and Override Parameters plus Exception Codes 10 Modbus Read Write and Override Parameters plus Exception Codes 10 1 Overview Introduction This section contains information concerning Reading Writing and Overriding parameters in this instrument There are two types of parameters e Data Transfer These parameters include reading control data option status and reading or changing setpoints e Configuration Data All the configuration data is listed in the order in which it appears in the controller Each type of parameter has the identifying codes listed with it What s in this section The following topics are covered in this section TOPIC See Page 10 1 Overview 113 See Page 19 10 2 Reading Control Data 1 Us 10 3 Miscellaneous Read Onlys 115 10 4 Configuration Parameters 116 10 5 Modbus RTU Exception Codes 125 General Information Non volatile Memory Retention e This controller uses non volatile memory to store configuration data These memories are guaranteed to retain data for a minimum of ten years as long as the data is not written and erased more than 10 000 times In order not to exceed this number it is strongly recommended that configurations which change rapidly such as Computer Setpoint use the Override feature which does not affect non volatile memory 3 07 UDC2500 Universal Digital Limit ControllerPr
35. 7 188 minus 12 568 millivolts or 4 62 millivolts e Use 1 54 millivolts for the Zero calibration value and 4 62 millivolts for the Span calibration value 0 to 10 Volts Refer to Figure 5 6 and wire the controller according to the procedure given in Table 5 8 Table 5 8 Set Up Wiring Procedure for 0 to 10 Volts 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 6 2 Place voltage source at zero before switching on 3 Do not switch voltage source ON OFF while connected to the instrument Volt Source oe Figure 5 6 Wiring Connections for 0 to 10 Volts 76 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Input Calibration Milliamperes Refer to Figure 5 5 and wire the controller according to the procedure given in Table 5 6 Table 5 9 Set Up Wiring Procedure for Milliampere Inputs 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 7 2 Place current source at zero before switching on 3 Do not switch current source ON OFF while connected to the instrument Milliampere ER 26 250 ohms e Source Su ER 27 Figure 5 7 Wiring Connections for 0 to 20 mA or 4 to 20 mA Inputs 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 77 Input Calibration 5 5 Input 1 Calibration Procedure Preliminary Steps e Apply power and allow the controller to warm up for 30 minutes before you calibrat
36. Feature Introduction The lockout feature in the UDC2500 is used to inhibit changes via keyboard of certain functions or parameters by unauthorized personnel Lockout levels There are different levels of Lockout depending on the level of security required These levels are e NONE No Lockout All groups Read Write e CAL All groups Read Write except Calibration e CONF Configuration parameters are Read only No writes permitted Calibration Group is not available e SP Only the Lockout group is available for Read Write Setpoint value is Read Only See Subsection 3 4 Lockout Parameters Set Up Group prompts to select one of the above Key error When a key is pressed and the prompt Key Error appears in the lower display it will be for one of the following reasons e Parameter not available or locked out e Not in setup mode press SET UP key first 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 51 Operating the Limit Coniroller 4 5 Monitoring Your Limit Controller Annunciators The following annunciator functions have been provided to help monitor the controller Table 4 2 Annunciators ALM 1 2 A visual indication of each alarm Blinking 1 indicates alarm latched and needs to be acknowledged before extinguishing when the alarm condition ends ForC A visual indication of the temperature units F Degrees Fahrenheit C Degrees Celsius Display Mode The displays and indicators on the operato
37. G 26 Configuration Prompt Hierarchy AA 27 Configuration Procedure 2u 28er RHABR ate eae 28 Lock Set Up Group u a een ni ete 29 E mit Set Up Group TEE 30 Input Be EE EE 31 Options Set Up Group Anna ee RE tn RR REIHE 35 Communications Set Up Group 37 Alarms Set Up GTOUP ra en vet toca N ee r A Ea NEEN 39 Display Set Up Group s cccpessess dines Meee Gites eeeieds gat REENEN Lee ee 43 P I E Tool Ethernet and Email Configuration Screen 45 Config ration Record Sheet unendliche 48 OPERATING THE LIMIT CONTROLLER eeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeeneeees 49 CON CL VIC W a Hl ege el Be ee RE see 49 Operator Intertace 256 iit hans lei shi HER RR HIER EIN eh 50 Entering a Security Code iur oaa oa ee ie aoit Sree 50 Lockout Feature una asien ars es Bin HR RE a 51 Monitoring Your Limit Controller ensage ie 52 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 4 6 Operating Your Limit Controller neuester ensenssesunerurersnesteken 54 4 1 Alarm Setpoint onise o eis ee ee iach ee ee evs ee ETA 57 4 8 RER Tool M intenanceScreense unenn ee rear ra 58 4 9 Configuring your Ethernet Connection uueesseesserssenseensensensnensnnennnennnesnnesnennsennsnnnseennnennn ern 64 5 INPUT GALIBRA PION nennen 69 e DER EE EE 69 5 2 Minimum and Maximum Range Values 2000 eee eesecssecsseceeceseceseeeseeeseeeeneesseeeaeeeaaecsaecaecnaeenaeees 70 5 3 Preliminary Informations EE 72
38. HIGH ALARM 2 SETPOINT 1 STATE Same as LOW A1S1HL ALHYST 0 0 to 100 0 of span or full ALARM HYSTERESIS A single adjustable output as appropriate hysteresis is provided on alarms such that when the alarm is OFF it activates at exactly the alarm setpoint when the alarm is ON it will not deactivate until the variable is 0 0 to 100 away from the alarm setpoint Configure the hysteresis of the alarms based on INPUT signals as a of input range span Configure the hysteresis of the alarm based on OUTPUT signals as a of the full scale output range ALARM1 LATCHING ALARM OUTPUT 1 Alarm output 1 can be configured to be Latching or Non latching NO LAT NO LAT Non latching LATCH LATCH Laitching ATTENTION When configured for latching the alarm will stay active after the alarm condition ends until the RUN HOLD key is pressed 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 41 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition BLOCK ALARM BLOCKING Prevents nuisance alarms when the controller is first powered up The alarm is suppressed until the parameter gets to the non alarm limit or band Alarm blocking affects both alarm setpoints DISABLE Disables blocking AL 1 Blocks alarm 1 only AL 2 Blocks alarm 2 only AL12 Blocks both alarms ATTENTION When enabled on power up or initial enabling via c
39. Installation COMMUNIGTION MASTER OR SWITCH SHLD TXD TXD RXD RXD 14 SHLD 15 RXD 16 RXD 17 TXD 18 TXD G Do not run the communications lines in the same conduit as AC power Correct connections may require the use of an Ethernet cross over cable Use Shielded twisted pair Category 5 STP CAT5 Ethernet cable G Use Switch rather than Hub to maximize performance Figure 2 11 Ethernet Communications Option Connections Figure 2 11 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 Table 2 6 Terminals for connecting a UDC to a MDI Compliant Hub or Switch UDC Terminal UDC Signal Name RJ45 Socket Pin Switch Signal Name Position 14 Shield Shield Shield Position 15 RXD 6 TXD Position 16 RXD 3 TXD Position 17 TXD 2 RXD Position 18 TXD 1 RXD Table 2 7 shows how to connect a UDC directly to a PC utilizing a straight through cable wiring the UDC cable this way makes the necessary cross over connections Table 2 7 Terminals for connecting a UDC directly to a PC utilizing a straight through cable UDC Terminal UDC Signal Name RJ45 Socket Pin PC Signal Name Position 14 Shield Shield Shield Position 15 RXD 2 TXD Position 16 RXD 1 TXD Position 17 TXD 6 RXD Position 18 TXD 3 RXD 3
40. L AX or W until the desired 100 output is read on the milliammeter Ka Gas 4 Exit the Calibration Mode The controller stores the span value To exit the calibration mode 6 3 Restore Output Factory Calibration Introduction The factory calibration constants for the Auxiliary Outputs are stored in its non volatile memory Thus you can quickly restore the Factory Calibration for those outputs by simply changing the ARANGE to the other setting and then changing it back to the original type Refer to Table 6 3 Restore Factory Calibration for procedure 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 85 Output Calibration ATTENTION A restored factory calibration overwrites any previous field calibration done for the output Protect your field calibration from accidental overwrites by configuring the appropriate LOCKOUT selection after calibration See Section 3 Configuration for specific instructions to set the lockout Table 6 3 Restore Factory Calibration an operation Pes Rew 1 Set LOCKOUT to C setup until you see NONE Ne Upper Display SET Lower Display TUNING kd Until you see Upper Display one of the following NONE all parameters are read write CAL all parameters are read write except Calibration CONF configuration parameters are Read Only no writes permitted VIEW Tuning and Setpoint Ramp parameters are read write No other parameters can be viewed ALL
41. LOW LOW ALARM A1S2TY ALARM 1 SETPOINT 2 TYPE Select what you want Setpoint 2 of Alarm 1 to represent The selections are the same as A1S1TYPE A1S2VA Value in engineering units ALARM 1 SETPOINT 2 VALUE This is the value at which you want the alarm type chosen in prompt A1S2TYPE to actuate The details are the same as A1S1 VAL A1S2HL HIGH ALARM 1 SETPOINT 2 STATE Same as LOW A1S1HL A2S1TY ALARM 2 SETPOINT 1 TYPE Select what you want Setpoint 1 of Alarm 2 to represent The selections are the same as A1S1TYPE ATTENTION Not applicable with Relay Duplex unless using Dual Relay PWA A2S1VA Value in engineering units ALARM 2 SETPOINT 1 VALUE This is the value at which you want the alarm type chosen in prompt A2S1TYPE to actuate The details are the same as A1S1 VAL A2S1HL HIGH ALARM 2 SETPOINT 1 STATE Same as LOW A1S1HL 40 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition A2S2TY Value in engineering units ALARM 2 SETPOINT 2 TYPE Select what you want Setpoint 2 of Alarm 2 to represent The selections are the same as A1S1TYPE ATTENTION Not applicable with Relay Duplex unless using Dual Relay PWA A2S2VA ALARM 2 SETPOINT 2 VALUE This is the value at which you want the alarm type chosen in prompt A2S2TYPE to actuate The details are the same as A1S1 VAL A2S1HL
42. 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 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 XXXX Figure 2 5 Mains Power Supply UDC2500 Universal Digital Limit ControllerProduct Manual 19 Installation 20 Input 1 Thermocouple RTD Millivolt or Volts except 0 10 Volts Use Thermocouple extension wire only Use Thermocouple extension wire only Po E wer Supply 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 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 This controller does not produce a steady current for burno
43. Output and if you have a model with communications you can configure the controller to alarm on SHED If you have setpoint programming you can alarm when a segment goes ON or OFF NO ALARM PROCESS VARIABLE DEVIATION SHED FROM COMMUNICATIONS FAILSAFE PV RATE OF CHANGE DIGITAL INPUT 1 ACTUATED THERMOCOUPLE WARNING NOTE 1 THERMOCOUPLE FAILING NOTE 2 ATTENTION NOTE 1 Thermocouple Warning means that the instrument has detected that the Thermocouple Input is starting to fail Not valid for input types other than Thermocouple NOTE 2 Thermocouple Failing means that the instrument has detected that the 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 39 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition Thermocouple Input is in imminent danger of failing Not valid for input types other than Thermocouple A1S1VA Value in engineering units ALARM 1 SETPOINT 1 VALUE This is the value at which you want the alarm type chosen in prompt A1S1TYPE to actuate The value depends on what the setpoint has been configured to represent No setpoint is required for alarms configured for Communications SHED This prompt does not appear for Alarm Types that do not use values For example A1S1TY MANUAL A1S1HL ALARM 1 SETPOINT 1 STATE Select whether you want the alarm type chosen in prompt A1S1TYPE to alarm High or Low HIGH HIGH ALARM
44. Output with Displayed Auxiliary Output Other symptoms If a set of symptoms or prompts other than the one you started with appears while troubleshooting re evaluate the symptoms This may lead to a different troubleshooting procedure If the symptom still persists refer to the installation section in this manual to ensure proper installation and proper use of the controller in your system 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 93 Troubleshooting Service 7 7 Troubleshooting Procedures Introduction The troubleshooting procedures are listed in numerical order as they appear in Table 7 4 Each procedure lists what to do if you have that particular failure and how to do it or where to find the data needed to accomplish the task WN WARNING SHOCK HAZARD TROUBLESHOOTING MAY REQUIRE ACCESS TO HAZARDOUS LIVE CIRCUITS AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT BEFORE SERVICING Equipment needed You will need the following equipment in order to troubleshoot the symptoms listed in the tables that follow e Multimeter Capable of measuring millivolts milliamps and resistance e Calibration sources T C mV Volt etc 94 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Procedure 1 Troubleshooting Service Table 7 5 explains how to troubleshoot power failure symptoms Table 7 5
45. RUP RST RST after power down the controller latching relay will have to be reset NORM NORM after power down the controller will operate normally in the same mode as before power was removed unless a limit has been exceeded If the limit was latched at power down the unit will be in Limit at power up and have to be reset SP_MAX 0 to 100 of input in HIGH SETPOINT LIMIT this selection engineering units prevents the setpoint from going above the value selected here The setting must be equal to or less than the upper range of the input 0 to 100 of input in LOW SETPOINT LIMIT this selection engineering units prevents the setpoint from going below the value selected here The setting must be equal to or greater than the lower range of the input DISPLY PROC Process Variable PV will be displayed in the upper display SP Setpoint if configured the setpoint will be displayed in the upper display SP will appear in the lower display 30 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Configuration 3 6 Input 1 Set Up Group Introduction This data deals with various parameters required to configure Input 1 Function Prompts Table 3 6 INPUT 1 Group Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition INITYP INPUT 1 ACTUATION TYPE This selection determines what actuation you are going to use for Input 1 B B Thermoc
46. SDENAB ENAB LIMIT LOW or ne ee HIGH HIGH TX DLY 30 POWRUP NORM WS FLT FP B SP MAX 1000 UNITS PCT ul S LOOPBK DIS DISPLY PROC INPUT1 INITYP KH ALARMS A1S1TY NONE XMITR1 LIN A1S1VA 90 IN1 HI 2400 A1S1HL HIGH IN1 LO 1 00 A1S2TY NONE BIAS 1 0 0 A1S2VA 90 FILTR1 1 0 A1S2HL HIGH BRNOUT UP A2S1TY NONE EMIS 1 0 A2S1VA 90 FREQ 60 A2S1HL HIGH DISPLY SP A2S2TY NONE A2S2VA 90 OPTIONS AUXOUT DIS A2S2HL HIGH 0 PCT 0 ALHYST 0 1 100 PCT 100 ALARM1 NOL CRANGE 4 20 BLOCK DIS DIGIN1 DIS DIAGAL DIS DISPLY DECML NONE UNITS F FREQ 60 LWRDSP ENAB TCDIAG ENAB 48 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Operating the Limit Controller 4 Operating the Limit Controller 4 1 Overview Introduction This section gives you all the information necessary to help you monitor your controller including an Operator Interface overview how to lockout changes to the controller entering a security code and monitoring the displays What s in this section The following topics are covered in this section TOPIC See Page 4 1 Overview 49 4 2 Operator Interface 50 4 3 Entering A Security Code 50 4 4 Lockout Feature 4 5 Monitoring The Limit Controller 52 4 6 How to Operate Your Limit Controller 54 4 7 Alarm Setpoints 57 4 8 PIER Tool Maintenance Screens 58 4 9 Configuring your Ethernet Connection 64 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 49 Operating the Lim
47. TDs and Radiamatics The equivalent PV signal is compared with the Limit set point If above Hi Limit or below Lo Limit a limit output relay is de energized When de energized the output relay locks out and remains in this state until the PV input signal drops below the high limit setpoint or rises above the low limit setpoint and the controller is reset manually from the front of the controller or through an optional external switch Check the configuration Make sure the Limit Controller has been configured to handle your process needs Refer to Section 3 Configuration for prompts and parameters e Input Parameters e Alarm Set Points and type e Limit Control Type high or low e External Reset Contact Input enable or disable e Power up Logic Reset relay on or Normal same as before power down e Lockout selection Power Up Logic Configurable power up logic lets you select the latching output relay to require RESET or to provide normal operation at power up If power to the limit controller fails and power is reapplied the controller goes through power up tests then starts in one of the following configurable conditions e Ifyou configured RST at setup group LIMIT the lower display will blink LIMIT at power up This will require reset via the M A RESET key or external switch to obtain normal operation e Ifyou configured NORM at setup group LIMIT the display and limit controller will func
48. ails The Ethernet Status screen shows the network status of the Ethernet Link This may be accessed either via Ethernet or via Infrared communications Not all diagnostic messages are available via Ethernet Communications For example if the Ethernet cable is unplugged then the instrument cannot send up the EUNPLGED diagnostic message via Ethernet Maintenance Ethernet Status Data Screen refreshes automatically if the communication link He is selected as Ethernet Tool provides manual refresh if communication link is selected as Infrared Ethemet Status NETWR KOK Device Type UDC3500 O14 Vi Figure 4 7 Ethernet Status Maintenance Screen 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 63 Operating the Limit Coniroller 4 9 Configuring your Ethernet Connection Introduction This controller is shipped from the factory with the address for Infrared IR communications set to 3 the Ethernet IP Address set to 10 0 0 2 the Ethernet Subnet Mask set to 255 255 255 0 and the Ethernet Default Gateway set to 0 0 0 0 Consult your Information Technologies IT representative as to how these should be configured for your installation The MAC address is printed on the product label located on the instrument s case Only the P I E Tool can be used to configure Ethernet parameters The figures in this section show screen shots from the PC version of the P LE Tool Screens Pocket PC Screens are g
49. al Inputs buttons allow you to see the current status of each alarm setpoint and digital input 58 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 3 07 Operating the Limit Coniroller Maintenance Loop Data tc Screen refreshes automatically if the communication link is selected as RS485 or Ethernet Tool provides manual refresh if communication link is selected as Infrared Select Loop Data Loot x PY OP1 GE OP2 Output OP3 Mode Alarm Digital Inputs Digital Inputs Status Device Type UDC3500 01A V1 Please wait Upload is in Progress Figure 4 3 Loop Data Maintenance Screen UDC2500 Universal Digital Limit ControllerProduct Manual 59 Operating the Limit Coniroller Loop Data Alarm Details This screen appears when you click on the Alarm button on the Loop Data Maintenance Screen and shows the status of each alarm setpoint NONE in the Type column indicates that the alarm is disabled Highlighted alarms are currently active An asterisk indicates that the alarm has changed state since the last communications transaction For this instrument the Alarm On and Alarm Off columns will always be blank See Section 3 9 for other information about configuring Alarms Maintenance Data Alarm Details cS Screen shows Alarm History Active Alarms are highlighted An indicates that Alarm status has changed since last update Screen re
50. al sales office Hardware and software related problems Use the troubleshooting error message prompts and controller failure symptoms to identify typical failures which may occur in the controller Follow the troubleshooting procedures to correct them 7 2 Troubleshooting Aids Overall error messages An error message can occur e At power up See Subsection 7 3 e When the Status Tests are requested See Subsection 7 4 e During continuous background tests while in normal operation See Subsection 7 5 Controller failure symptoms Other failures may occur that deal with the Power Output or Alarms Refer to the controller failure symptom in Table 7 4 to determine what is wrong and the troubleshooting procedures to use to correct the problem Check installation If a set of symptoms still persists refer to Section 2 Installation and ensure proper installation and proper use of the controller in the system 88 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Troubleshooting Service Determining the software version Table 7 1 lists the procedure for identifying the software version number Table 7 1 Procedure for Identifying the Software Version o a Upper Display READ Lower Display STATUS Set Up Group a 2 Read the software Function You will see version Upper Display Software version number 26xx Lower Display VERSION Please give this number to the Customer Support person It will indicate
51. alibration Mode 80 86 Calibration Steps 70 CE Conformity Europe 6 Communicationaddress 121 Communications Failure 98 Communications Modes Of Operation 114 Communications Set Up Group 37 Communications Station Address 37 Communications Transfer Rates 114 Communications Type 121 Composite Wiring Diagram 18 Configuration 26 Configuration Parameters 116 Configuration Procedure 28 Configuration Prompt Hierarchy 27 Configuration Record Sheet 48 Contact Input 56 Control Relays 13 Control Alarm Circuit Wiring 16 Controller Failure Symptoms 93 Controller Grounding 16 Controller Output Types 9 Index 13 Index D Decimal Point 43 Deviation 35 Diagnostic Alarm 123 Digital Input Option 56 Digital Inputs 8 35 Digital Parameters 114 Dimensions 14 Display 30 Display Mode 52 Display Set Up Group 43 E Electrical Considerations 16 Electrical Noise Precautions 17 Electromechanical Relay Output 21 Email Configuration Screen 46 Emissivity 34 Environmental And Operating Conditions 10 Equipment You Will Need To Calibrate 72 Error Messages 53 Ethernet Communications Address 66 67 Ethernet Communications Option Connections 23 Ethernet Configuration Screen 45 Ethernet Connection 64 Ethernet IP Address 127 Ethernet Status 63 Ethernet TCP IP 37 127 Ethernet TCP IP Communications Interface 9 External Interface Option Connections 22 24 External Reset 56 External Wiri
52. amatic Thermocouple Differential Millivolts or Volts Except 0 to 10 Volts 75 Table 5 7 Procedure to determine calibration voltages for Thermocouple Differential input types other than the Factory Setting 75 Table 5 8 Set Up Wiring Procedure for 0 to 10 Volts 76 Table 5 9 Set Up Wiring Procedure for Milliampere Inputs 77 Table 5 10 Input 1 Calibration Procedure 78 Table 5 11 Restore Input Factory Calibration 80 Table 6 1 Set Up Wiring Procedure for Auxiliary Output 84 Table 6 2 Auxiliary Output Calibration Procedure 85 Table 6 3 Restore Factory Calibration 86 Table 7 1 Procedure for Identifying the Software Version 89 Table 7 2 Procedure for Displaying the Status Test Results 90 Table 7 3 Background Tests 91 Table 7 4 Controller Failure Symptoms 93 Table 7 5 Troubleshooting Power Failure Symptoms 95 Table 7 6 Troubleshooting Latching Output Relay Failure 96 Table 7 7 Troubleshooting Alarm Relay Output Failure 96 Table 7 8 Troubleshooting a Keyboard Failure 97 Table 7 9 Troubleshooting a RS 485 Communications Failure 98 Table 7 10 Troubleshooting Auxiliary Output Failure 99 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual vii Table 7 11 Restoring Factory Configuration Table 8 1 Parts Identification Table 8 2 Parts Not Shown Table 9 1 Integer Parameter Type Table 9 2 Floating Point Parameter Type Table 9 3 Register Address Format for Function Code 20 Table 9 4 Register Address Format for Function Code 21 Table 10 1 Control D
53. an be configured over this link The number of units that can be configured depends on the link length with 31 being the maximum for short link lengths and 15 drops being the maximum at the maximum link length ATTENTION FM Models cannot have parameters changed write transactions via communications parameters can only be changed via the keyboard Function Prompts Table 3 8 Communications Group Function Prompts Function Prompt Selection or Range of Parameter Lower Display Setting Definition Upper Display ComADR 1 to 99 COMMUNICATIONS STATION ADDRESS This is a number that is assigned to a controller that is to be used with the communications option This number will be its address This parameter is also used for the IR communications link COMSTA COMMUNICATIONS SELECTION DIS DISABLE Disables the communications option MODB MODBUS Enable Modbus RTU communications ETHR ETHERN Enable Ethernet communications IRENAB DIS INFRARED COMMUNICATIONS EnAB Enables Disables the IR Port BAUD BAUD RATE is the transmission speed in bits per second 4800 BAUD 9600 BAUD 19200 BAUD 38400 BAUD 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 37 Configuration Function Prompt Selection or Range of Lower Display Setting Upper Display Parameter Definition you to force the UDC to delay its response for a time period of from 1 to 500 milliseconds compatible with the host system hardware software This param
54. ard is faulty by running a LOCAL terminals Run the Local Loopback Test LOOPBACK TEST Press SET UP key until you see If the test fails replace the board Upper Display If the test passes the problem is most likely elsewhere in the communications network Lower Display COM Press FUNCTION key until you see Upper Display DISABLE Lower Display LOOPBACK a or Y you will see Upper Display ENABLE Press Se o bg u g a ei D lt LOOPBACK The test will run until the operator disables it here 98 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Procedure 6 3 07 Troubleshooting Service Table 7 10 explains how to troubleshoot AuxiliaryProportional Output failure symptoms 1 Table 7 10 Troubleshooting Auxiliary Output Failure Step What to do How to do it Make sure the controller is configured for Auxiliary Output and the proper range 4 to 20 or 0 to 20 is configured Check the field wiring Check the output Recalibrate the Auxiliary output Change Auxiliary Output board Change Controller Make Options Set Up group function prompt AUX OUT any selection other than NONE If this prompt does not show up check if DIG IN 2 is enabled If so then as Auxiliary Ouptut and Digital Input 2 are mutually exclusive you must chose which one of these features you wish to use Make the Options Set UP group function prompt CRANGE 4 20 or 0 20 per your application Re
55. ariable Deviation PV Rate Communication Shed or Thermocouple Health A single adjustable hysteresis of 0 0 to 100 0 is provided Alarm Relay Contacts Rating Resistive Load 5 amps at 120 Vac or 240 Vac or 30 Vdc Isolation Functional Analog Inputs are isolated from all other circuits at 850Vdc for 2 seconds but not from each other Analog Outputs are isolated from all other circuits at 850Vdc for 2 seconds AC Power is electrically isolated from all other inputs and outputs to withstand a HIPOT potential of 1900Vdc for 2 seconds per Annex K of EN61010 1 Relay Contacts with a working voltage of 115 230 Vac are isolated from each other and all other circuits at 345Vdc for 2 seconds RS422 485 Modbus RTU Communications Interface Optional Baud Rate 4800 9600 19 200 or 38 400 baud selectable Data Format Floating point or integer Length of Link 2000 ft 600 m max with Belden 9271 Twinax Cable and 120 ohm termination resistors 4000 ft 1200 m max with Belden 8227 Twinax Cable and 100 ohm termination resistors Link Characteristics Two wire multi drop Modbus RTU protocol 15 drops maximum or up to 31 drops for shorter link length Ethernet TCP IP Communications Interface Optional Type 10Base T Length of Link 330 ft 100 m maximum Link Characteristics Four wire single drop five hops maximum IP Address IP Address is 10 0 0 2 as shipped from the Factory Recommended network configuration Use Sw
56. ata 2 registers IEEE 32 bit floating point 128 to 255 0080 to OOFF integer formatted data 1 register 16 bit integer 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 107 Modbus RTU Function Codes 9 3 1 Read Configuration Examples Example 1 108 The following is an example of a request to read the Gain 1 value using Function code 20 Request Message Read Gain 1 ID Tag 001 02 14 07 06 00 03 00 01 00 02 CRC16 Where 02 Address 14 Function Code 20 14 hex 07 Byte Count 06 Reference Type 00 03 File Number Access Data Value 00 01 Register Address Standard Access Gain 1 Tag ID 1 0002 Register Count Floating Point Data CRC16 This is the response to the above request Response Message 02 14 06 05 06 3F CO 00 00 CRC16 Where 02 Address 14 Function Code 20 14 Hex 06 Byte Count 05 Sub Message Length 06 Reference Type IEEE Floating Point 3F C0 0000 1 50 Value of Proportional Band CRC16 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Modbus RTU Function Codes Example 2 The following is another example of a request and response message using Function code 20 Request Message Read LSP 1 ID Tag 39 and LSP 2 ID Tag 53 02 14 OE 06 00 03 00 27 00 02 06 00 03 00 35 00 02 CRC16 Where 02 Address 14 Function Code 20 14 Hex OE Byte Count 06 Reference Type IEEE Floating Point 00 03 File Number Ac
57. ata Parameters Table 10 2 Miscellaneous Read Onlys Table 10 3 Set up Group Lock Table 10 4 Set up Group Limit Table 10 5 Set up Group Input 1 Table 10 6 Set up Group Options Table 10 7 Set up Group Communications Table 10 8 Set up Group Alarms Table 10 9 Set up Group Display Table 10 10 Modbus RTU Data Layer Status Exception Codes viii UDC2500 Universal Digital Limit ControllerProduct Manual 100 102 102 105 105 107 111 115 115 116 117 118 120 121 122 124 126 3 07 Figures Figure 1 1 UDC2500 Operator Interface 2 Figure 1 2 Screen capture of Process Instrument Explorer running on a Pocket PC 4 Figure 1 3 Depiction of infrared communications 5 Figure 2 1 Model Number Interpretation 12 Figure 2 2 Mounting Dimensions not to scale 14 Figure 2 3 Mounting Method 15 Figure 2 4 Composite Wiring Diagram 18 Figure 2 5 Mains Power Supply 19 Figure 2 6 Input 1 Connections 20 Figure 2 7 Electromechanical Relay Output 21 Figure 2 8 Solid State Relay Output 21 Figure 2 9 Open Collector Output 22 Figure 2 10 RS 422 485 Communications Option Connections 22 Figure 2 11 Ethernet Communications Option Connections 23 Figure 2 12 Auxiliary Output and Digital Inputs Option Connections 24 Figure 2 13 Transmitter Power for 4 20 mA 2 wire Transmitter Using Open Collector Alarm 2 Output24 Figure 2 14 Transmitter Power for 4 20 mA 2 Wire Transmitter Using Auxiliary Output 25 Figure 2 15 Limit Controller Applicatio
58. ation Examples A 108 9 4 Function Code 21 15h Write Configuration Reference Data 110 Hat Write Configuration Ex mples 2 2 ernennen dere 112 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 10 MODBUS READ WRITE AND OVERRIDE PARAMETERS PLUS EXCEPTION CODE Siva u aa rasanan rro aeaa aiie aae aaa Aaaa Anai aa ann ana 113 191 Overview era a aE AE Aa E DEAE ROO 113 10 2 Reading Control Data 2 1 2 mn era eee E A EER e 115 10 3 Miscellaneous Read OnlyS 2u u 2 20 2 ae nee eng evans ce ie 115 10 3 1 Register Addresses for Read Onlys 0 ee cescesceseceseceseceseeeseeeeeeesaeeeaeeeaaecaaecaeenaeenaeens 115 10 4 Configuration Parameters 2 ne 22 Ee dE RIES AE e AS 116 10 4 1 Lock Eee A soca oan Renee ne ee 116 10 4 2 Limit ee AE ER ae eg tee ee pees 117 10 4 3 put EE 118 10 4 4 de 120 10 4 5 COMMUNICATIONS Hi hseseefeees Shaws estes s Hawt ec gietse ee ge Miele ehh aie 121 10 4 6 E EEN 122 10 4 7 KETTER 124 10 5 Modbus RTU Exception Codes AAA 125 11 ETHERNET TCP IP anna 127 11 1 OA EE 127 L FURTHER INFORMATION sicicicssctesccccccssnssccceccccacesarassnenscecsucsssaneuancnacecdescasasenana 128 12 1 Modbus RTU Serial Communications 000 0 eeceeceeceeeeeeeeeeeaeeeseecseecaecaecsaeceaeeseeeseeeseeees 128 12 2 Modbus Messaging on TCP IP AAA 128 12 3 Howto Apply Digital Instrumentation in Severe Electrical Noise Environments 128 MINE Rena Gas aaa sa tain ida
59. ave 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 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 5 Introduction 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
60. cess Data Value 00 27 Register Address Standard Access LSP 1 ID Tag 39 00 02 Register Count to read Floating Point Data 06 Reference Type IEEE Floating Point 00 03 File Number Access Data Value 00 35 Register Address Standard Access LSP 2 ID Tag 53 00 02 Register Count to read Floating Point Data CRC16 This is the response to the above request Response Message 02 14 0C 05 06 43 C8 00 00 05 06 44 60 00 00 CRC16 Where 02 Address 14 Function Code 20 14 Hex OC Byte Count 05 Data Byte Count Sub Message Length 06 Reference Type IEEE Floating Point 43 C8 0000 400 0 Value of Local Setpoint 1 05 Data Byte Count Sub Message Length 06 Reference Type IEEE Floating Point 44 600000 896 0 Value of Local Setpoint 2 CRC16 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 109 Modbus RTU Function Codes 9 4 Function Code 21 15h Write Configuration Reference Data Introduction Function Code 21 15 Hex is used in this instrument to allow writes of integer and floating point values to the configuration database and override values The configuration database of this instrument is located in EEROM The override values are stored in RAM Integer format is used to write to Digital configuration items Floating Point format is used to write to Analog configuration items as defined by the configuration ID tags Write Restrictions Care should be tak
61. d resists the effects of vibration and shock Figure 1 1 UDC2500 Operator Interface 2 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Introduction 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 g KS Function 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 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 D Selects an operating parameter to be shown in the lower display J a MAN AUTO This function is not available on the Limit Controller RESET Reset the Limit Relay H eS This key does not function on the Limit Controller Nw Acknowledges a latched alarm 1 e Acknowledges Diagnostic Messages e Increases the selected parameter value Kb e Decreases the selected parameter value 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 3 Introduction 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 e C
62. e e Please read Subsection 5 4 Input I Set Up Wiring before beginning the procedure e Make sure you have LOCK set to NONE See Subsection 3 4 e See Table 5 1 for Voltage vs Resistance equivalents or 0 and 100 range values CAUTION For linear inputs avoid step changes in inputs Vary smoothly from initial value to final 100 value Procedure The calibration procedure for Input 1 is listed in Table 5 10 The numeric codes are also listed Table 5 10 Input 1 Calibration Procedure as Seat press Rew 1 Enter Calibration setup Upper Display CAL Mode Nae Lower Display INPUT1 until you see ki N Youwill see oe Upper Display DIS Lower Display CALIN1 The calibration sequence is enabled and you will see Upper Display BEGN Lower Display CALIN1 At the completion of the sequence the selection automatically reverts to disable 2 Calibrate 0 Function You will see Upper Display APLY Lower Display IN1ZRO e Adjust your calibration device to an output signal equal to the 0 range value for your particular input sensor See Table 5 1 for Voltage Degrees or Resistance equivalents for 0 range values e Wait 15 seconds then go to the next step 3 Calibrate 100 Function You will see Upper Display APLY 78 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Input Calibration sep zem mess Re Lower Display IN1SPN e Adjust your calibration device to an outp
63. ection provided by the equipment may be impaired 6 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Installation 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 22 condensed Seaton SSCS E E E swe ooo fa 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 2 8 Limit Control Application Diagram 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 7 Installation Pre installation Information If the controller has not been removed from its shipping carton inspect the carton for damage then remove the controller e Inspect the unit for any obvious shipping damage and report any damage due to transit to the carrier e Make sure a bag containing mounting hardware is included in the carton with the controller e Check that the model numb
64. en not to exceed the 100 000 write limit of the EEROM Request and Response Formats The Request and Response formats for Function code 21 15 Hex are shown below Details for each block reference follow Request Message Format The register address is interpreted as the tag ID configuration number For Infrared Transactions add three BOFs COhex at the beginning of each message and one EOF FFhex at the end of each message Reference Type Definitions The Reference Type definition is always 06 See examples in Subsection 9 4 1 110 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Modbus RTU Function Codes File Number The file number word contains the register number from the register address structure shown in Table 9 1 and Table 9 2 Although the register address structure tables indicate up to 13 data registers are available for access only register address 3 is currently supported Register Address The register address is used to designate the tag ID number for the parameter being accessed The register address is made up of two bytes the MSB 00 always The LSB contains the RS422 tag ID number The tag ID numbers represent the parameter s register address es See Section 10 for the tag ID numbers Table 9 4 Register Address Format for Function Code 21 Register Register Address es Address es Dec Hex 001 to 125 0001 to 007D analog formatted data 2 registers IEEE 32 bit fl
65. enerally similar in format but smaller The P I E Tool can connect to your controller via either Ethernet communications port or the Infrared IR communications port Configuring the Controller via Infrared Communications 64 If connecting via IR and assuming that the instrument s IR address has not been changed from its factory setting of 3 then configure your Communications Type as Infrared and your IR address to 3 as shown below Select PC COMM Setup then select Infrared CommunicationT ype PC Comm Infrared e Setup D Select Type to setup z E Lnlaad Communication Setup Infrared gt Screen helps to setup Infrared parameters Infrared parameters Device Address Serial Port Gk Cancel Figure 4 8 IR Communications Address UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Operating the Limit Coniroller Close the IR configuration window and then single click on the Online Configuration button Configuration Press any button on the controller s keyboard to activate the controller s IR port Point your IR dongle if using PC or your Pocket PC s IR port if using Pocket PC at the IR window on the front of the controller and then click on the Start button The P LE Tool should start uploading the configuration information from the controller as shown below Online Configuration gt To terminate Upload click
66. er shown on the inside of the case agrees with what you have ordered 2 2 Condensed Specifications We recommend 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 Inputs 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 Both inputs are 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 50 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 Inpu
67. es of 100 0 and above can be shown UNITS TEMPERATURE UNITS This selection will affect the indication and operation F DEG F Degrees Fahrenheit C DEG C Degrees Centigrade NONE NONE No display of units FREQ POWER LINE FREQUENCY Select whether your controller is operating at 50 or 60 Hertz E ATTENTION For controllers powered by 24 Vdc this configuration should be set to the AC line frequency used to produce the 24 Vdc supply Incorrect setting of this parameter can cause normal mode noise problems in the input readings LWRDSP LOWER DISPLY Select whether the unit uses single or dual display ENAB ENAB Enable Dual Display DIS DIS Disable Dual Display Single Display Only 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 43 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition TCDIAG THERMOCOUPLE DIAGNOSTICS Enable or disable Thermocouple diagnostic messages ENAB ENAB Enable Diagnostic Messages DIS DIS Disable Diagnostic Messages 44 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Configuration 3 11P 1 E Tool Ethernet and Email Configuration Screens Introduction These screens only appear in instruments that have Ethernet Communications Ethernet and Email parameters can only be configured via the Process Instrument Explorer P LE Tool The figures in this section show scree
68. eter is also used for the IR communications link TX_DLY 1 to 500 milliseconds TX DELAY Configurable response delay timer allows 1 2 3 exponent m mantissa bit WS_FLT Defines word byte order of floating point data for communications Byte values 0 seeeeeee emmmmmmm mmmmmmmm mmmmmmmm Where s sign e SDENAB DIS SHED ENABLE Disables enables shed EnAB functionaliy from communications Each period equals 1 3 seconds 0 equals No shed Note If ComSTA is set to MODBUS and if SHEDENAB is set to DISABL Shed Time will not be configurable SHDTIM 0 to 255 Sample Periods SHED TIME The number that represents how many sample periods there will be before the controller sheds UNITS PCT PERCENT EGR ENGINEERING UNITS LOOPBK LOCAL LOOPBACK tests the communications hardware DIS DISABLE Disables the Loopback test ENAB ENABLE Allows loopback test The UDC goes into Loopback mode in which it sends and receives its own message The UDC displays PASS or FAIL status in the upper display and LOOPBACK in the lower display while the test is running The UDC will go into manual mode when LOOPBACK is enabled with the output at the Failsafe value The test will run until the operator disables it here or until power is turned off and on ATTENTION connected to the external communications link in order to perform this test If it is connected only one instrument should run the loopback test at a time The host com
69. fer to Section 3 Configuration Output impedance must be less than or equal to 1000 ohms Change the AUX OUT selection to OUTPUT Put the controller into Manual mode and change the output from 0 to 100 4 20 mA Use a DC milliammeter at the rear terminals to verify the output Refer to Section 6 Output Calibration for details Installation instructions provided with new board UDC2500 Universal Digital Limit ControllerProduct Manual 99 Troubleshooting Service 7 8 Restoring Factory Configuration Introduction This procedure restores the configuration of the instrument back to the Factory Settings per Section 3 12 ATTENTION Restoring the factory configuration overwrites all user entered configuration changes This procedure cannot be undone it is a one way process Table 7 11 explains how to restore Factory Configuration Table 7 11 Restoring Factory Configuration Step What to do 1 Turn off the power to the instrument for at least five seconds 2 Turn the power back on and simultaneously press the FUNCTION and A buttons This must be done while TEST DONE is being displayed 3 If step 2 was performed correctly the instrument will now display UDC Upper UPDATE Lower 4 Press the Function Key The instrument will now display CFG RESTORE 5 Press the Function Key The instrument will now display DOIN RESTORE 6 When the instrument finishes
70. fic user defined function codes Where differences occur between the two protocols it will be noted Several standard Modbus RTU function codes are supported Configuration ID Tags Function codes 20 and 21 use the RS422 485 tag IDs for accessing configuration and process related data These tags are fully explained in Section 10 The tag IDs represent the register addresses used in the Request Message Other Modbus Codes For Modbus codes other than for accessing configuration and process related data for this controller refer to the Modbus RTU Serial Communications User Manual 51 55 25 66 104 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Modbus RTU Function Codes Register Address Structure Table 9 1 Integer Parameter Type Register Numbers Dec 2 Read Write Value 16 bit integer Read Write WE 4 NotUsed LNOTSUEEORTED 1 Low Range 16 bit integer NOT SUPPORTED o O 6 NotUsed NOTSUPPORTED 1 7 LH Range 16 bit Integer NOT SUPPORTED 8 NotUsed NOTSUPPORTED 9to13 Description Text ASCII string NOT SUPPORTED Table 9 2 Floating Point Parameter Type Register Numbers Dec Type 2 NOTSUPPORTED Type 2 NOT SUPPORTED IEEE Floating Point Attribute NOT SUPPORTED 1 Read Only 2 Read Write Value float high word Read Write po Low Range float high word NOT SUPPORTED 3 Low Range float low word NOT SUPPORTED
71. for Relay Contact information Procedure 3 Table 7 7 explains how to troubleshoot Alarm Relay Output failure Table 7 7 Troubleshooting Alarm Relay Output Failure Step What to do How to do it 1 Check the alarm configuration Reconfigure if necessary data If it is correct check the Refer to Section 3 Configuration for field wiring details 2 Check that the applicable alarm If the alarm type is set for PV place the relay actuates properly controller in manual mode Vary the input depending on what you have set to raise and lower the PV around the at prompt AxSxTY setpoint Listen for a click from the relay as the PV moves in either direction and If it does check the field wiring note that the proper ALM or ALME is lit 3 Check the contacts Make sure the NO or NC contact wiring is correct Refer to Section 2 Installation for relay contact information 4 Change the relay and or the Installation instructions supplied with the current output board new relay or board 5 Change MCU board Installation instructions supplied with the new board 96 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Procedure 4 Troubleshooting Service Table 7 8 explains how to troubleshoot a Keyboard failure Table 7 8 Troubleshooting a Keyboard Failure Step What to do How to do it 1 4 Make sure the keyboard is connected properly to the MCU output and power input boa
72. for a particular application CAUTION The field calibration will be lost if a change in input type configuration is implemented at a later time The original factory calibration data remains available for later use after a field calibration is done See subsection 5 6 if you want to restore factory calibration values What s in this section The following topics are covered in this section 5 1 Overview 5 2 Minimum and Maximum Range Values 70 5 4 Input 1 Set Up Wiring 73 5 5 Input 1 Calibration Procedure 78 5 3 Preliminary Information 5 6 Restore Input Factory Calibration 79 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 69 Input Calibration Calibration Steps Use the following steps when calibrating an input 1 Find the minimum and maximum range values for your PV input range from Table 5 1 2 Disconnect the field wiring and find out what equipment you will need to calibrate 3 Wire the calibrating device to your controller according to the set up wiring instructions for your particular input Subsection 5 4 4 Follow the calibration procedure given for Input 1 Subsection 5 5 5 2 Minimum and Maximum Range Values Select the Range Values Calibrate the controller for the minimum 0 and maximum 100 range values of your particular input type Two input controllers will need to have each input calibrated separately Select the Voltage Current or Resistance equivalents for 0 and 100
73. for the Thermocouple Type you will be using 2 Find the thermoelectric voltage for the desired operating temperature 3 Find the thermoelectric voltages for the temperatures 50 F and 150 F away from the desired operating temperature 4 The zero calibration voltage will be thermoelectric voltage for the 50 F temperature minus the thermoelectric voltage for the desired operating temperature This will be a negative voltage 5 The span calibration voltage will be thermoelectric voltage for the 150 F temperature minus the thermoelectric voltage for the desired operating temperature This will be a positive voltage 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 75 For example Determine the calibration voltage values for a pair of J type thermocouples at an operating temperature of 450 F this is equivalent to the Factory setting e The ITS 90 standard for the J thermocouple shows that the thermoelectric voltage for 450 F is 12 568 millivolts e The 50 F point would be 400 F The ITS 90 standard shows that the thermoelectric voltage for 400 F is 11 025 millivolts e The 150 F point would be 600 F The ITS 90 standard shows that the thermoelectric voltage for 600 F is 17 188 millivolts e The zero calibration voltage is thus 11 025 minus 12 568 millivolts or 1 543 millivolts this can be rounded off to 1 54 millivolts without significant loss of accuracy e The span calibration voltage is thus 1
74. freshes automatically if the communication link is selected as RS485 or Ethernet Tool provides manual refresh if communication link is selected as Infrared Alarm Type Event Value Actual Alarm On Alarm Off Alarm1 SP1 IN 1 HIGH END 500 00 249 99 Alarm SP2 NONE LOW BEGIN 0 00 0 00 Alarm2 SP1 NONE LOW BEGIN 0 00 0 00 Alarm2 SP2 NONE LOW BEGIN 0 00 0 00 Figure 4 4 Alarm Details Maintenance Screen 60 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Operating the Limit Coniroller Loop Data Digital Input Details 3 07 This screen appears when you click on the Digital Inputs button on the Loop Data Maintenance Screen and shows the status of each Digital Input NONE in the Type column indicates that the Digital Input is disabled Highlighted Digital Inputs are currently active An asterisk indicates that the alarm has changed state since the last communications transaction This instrument has a maximum of two Digital Inputs Maintenance Data Digital Input Details c Screen shows Digital Input details Here Active Digital Inputs are highlighted Also Indicates status has changed since last View Digital Input Type _ Combination Status NONE DIS Open NONE DIS Open NONE DIS Open NONE DIS Open NONE DIS Open NONE DIS Open NONE DIS Open Close Figure 4 5 Digital Input Details Screen UDC2500 Universal Digital Limit ControllerProduct Manual 61 Operating
75. g smtp your_isp com UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 3 07 Configuration The content of the Emails sent by this controller contains the Alarm that triggered the Email its settings and the current value if applicable of the monitored variable For example the content of an Email triggered by Alarm 1 Setpoint 1 that is configured to monitor Input 1 would look something like this Name Alarm 1 SP1 Type INPUTI Event HIGH END Value 500 00 Actual 712 69 The content of an Email triggered by Alarm 2 Setpoint 1 that is configured to monitor Digital Input 1 would look something like this Name Alarm 2 SP1 Type DIG IN1 Event HIGH END Value 0 00 Actual 0 00 ATTENTION Email will always be time stamped with the date that the Ethernet Software in the instrument was last modified If the SMTP address on your network is changed such as can happen when a server is replaced then you must reconfigure the Email SMTP IP address in this instrument to match UDC2500 Universal Digital Limit ControllerProduct Manual 47 Configuration 3 12 Configuration Record Sheet Enter the value or selection for each prompt on this sheet so you will have a record of how your controller was configured Group Function Value or Factory Group Function Value or Factory Prompt Prompt Selection Setting Prompt Prompt Selection Setting LOCK SECUR DIS COM ComADR 3 LOCK CAL ComSTA DIS IRENAB ENAB
76. gister Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Auxiliary 009E 158 INT R W 0 None Output 1 Not Used 2 Not Used 3 PV Low Scaling 0031 049 FP R W Within the range of the Factor selected variable in ID 34 158 High Scaling 0032 050 FP R W Within the range of the Factor selected variable in ID 434 158 Auxiliary 00EC 236 INT R W 0 4 20 mA Output Range 1 0 20 mA Digital Input O0BA 186 INT R W 0 None 1 External 1 Enable Reset 2 External Reset Only 120 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 10 4 5 Modbus Read Write and Override Parameters plus Exception Codes Communications Table 10 7 lists all the register addresses and ranges or selections for the function parameters in Set up Group Communications Parameter Description Communications Type Floating Point Byte Order Shed Time Comm Data Units 3 07 Table 10 7 Set up Group Communications Register Address Hex Decimal Data Access Type FP R W Communication 004D 77 1 99 Address IR Port Enable OOF1 241 INT R W 0 Disable 1 Enable Transmit Delay 004E 78 FP R W Response Delay in ms 1 to 500 6ms Data Range or Enumerated Selection 0 None 1 Disable 2 RS 485 Modbus 3 Ethernet 0 Big Endian 1 Big Endian Byte Swap 2 Little Endian 3 Little Endian Byte Swap
77. hall 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 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 mm copper conductor is recommended Control Alarm Circuit Wiring 16 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 gt 30 Vac 42 4 Vpeak or 60 Vdc wiring per Permissible Wiring Bundling Table 2 5 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Installation Electrical Noise Precautions Electrical noise is composed of unabated electrical signals which produce undesirable
78. he upper display back to the proper selection You will see Upper Display Original Input Selection that matches your type of sensor Lower Display INxTYP 4 Return to Normal cs to return to Normal operating mode Operation Na The factory calibration will be restored 80 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Input Calibration 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 81 Output Calibration 6 Output Calibration 6 1 Overview Introduction This section describes the field calibration procedures for the Auxiliary Output What s in this section The following topics are covered in this section 6 2 Auxiliary Output Calibration 6 3 Restore Output Factory Calibration A WARNING SHOCK HAZARD OUTPUT CALIBRATION MAY REQUIRE ACCESS TO HAZARDOUS LIVE CIRCUITS AND SHOULD ONLY BE PERFORMED BY QUALIFIED SERVICE PERSONNEL MORE THAN ONE SWITCH MAY BE REQUIRED TO DE ENERGIZE UNIT BEFORE CALIBRATION 6 2 Auxiliary Output Calibration Introduction Calibrate the controller so that the auxiliary output provides the proper amount of current over the desired range The controller can provide an auxiliary current output range of from 0 mA to 20 mA and can be calibrated at 4 mA for 0 of output and 20 mA for 100 of output or any other values between 0 mA and 21 mA Equipment Needed You will need a calibrating device with whatever accuracy is required capable of measuring 0 to 20 mA Ca
79. hermocouples 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 Features e 90 264 Vac or 24 Vac dc Power Supply e Input Output Isolation e Isolated Auxiliary Current Output Digital Inputs e Modbus RS 485 or Ethernet TCP IP Communications 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
80. hex at the end of each message Byte Count The Byte Count equals the number of bytes transmitted in either the request or response message and will be the minimum number required to transmit all requested data 106 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Modbus RTU Function Codes Data Byte Count The Data Byte Count is the number of data bytes of the sub response including the Reference Type but not including itself A floating point sub response has four bytes of data and one byte representing the reference type making the data byte count equal to five Reference Type Definitions The Reference Type definition is always 06 See examples in Subsection 9 3 1 File Number The file number word contains the register number from the register address structure tables on page 3 Although the register address structure tables indicate up to 13 data registers are available for access only register address 3 is currently supported Register Address The register address word represents the tag ID number for the parameter s being accessed The register address word is made up of two bytes the MSB 00 always The LSB contains the tag ID number The tag ID numbers represent the parameter s register address es See Section 3 for the tag ID numbers Table 9 3 Register Address Format for Function Code 20 Register Register Address es Address es Decimal Hex 001 to 125 0001 to 007D analog formatted d
81. it Coniroller 4 2 Operator Interface Introduction Figure 5 1 is a view of the Operator Interface A description of the displays and indicators is included Figure 4 1 Operator Interface 4 3 Entering a Security Code Introduction The level of keyboard lockout may be changed in the Set Up mode However knowledge of a security code number 0 to 9999 may be required to change from one level of lockout to another When a controller leaves the factory it has a security code of 0 which permits changing from one lockout level to another without entering any other code number Procedure If you require the use of a security code select a number from 0001 to 9999 and enter it when the lockout level is configured as NONE Thereafter that selected number must be used to change the lockout level from something other than NONE NOTICE Write the number on the Configuration Record Sheet in the configuration section so you will have a permanent record 50 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Operating the Limit Coniroller Table 4 1 Procedure to Enter a Security Code step Operon Pess Rew 1 Enter Set Up setup Upper Display SET UP Mode ee Lower Display LOCK 2 Select any Set Function Upper Display 0 Up Grou e j P S Lower Display SECUR 3 Security Code A or To enter a four digit number in the upper display Entry 0001 to 9999 This will be your security code 4 4 Lockout
82. itch rather than Hub in order to maximize UDC Ethernet performance Infrared Communications Optional Type Serial Infrared SIR Length of Link 3 ft 1 m maximum for IrDA 1 0 compliant devices Baud Rate 19 200 or 38 400 baud selectable Power Consumption 20 VA maximum 90 to 264 Vac 15 VA maximum 24 Vac dc Power Inrush Current 10A maximum for 4 ms under operating conditions reducing to a maximum of 225 mA 90 to 264 Vac operation or 750 mA 24 Vac dc operation after one second CAUTION When applying power to more than one instrument make sure that sufficient power is supplied Otherwise the instruments may not start up normally due to voltage drop from the inrush current 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 9 Installation Weight 3 Ibs 1 3 kg Environmental and Operating Conditions Parameter Reference Rated Operative Transportation and Limits Storage Ambient Temperature 25 3 C 15 to 55 C 0 to 55 C 40 to 66 C 7745 F 58 to 131 F 32 to 131 F 40 to 151 F Relative Humidity 10 to 55 10 to 90 5 to 90 5 to 95 Vibration Frequency Hz 0 0 to 70 0 to 200 0 to 200 Acceleration g 0 0 4 0 6 0 5 Mechanical Shock Acceleration g 0 1 5 20 Duration ms 0 30 30 30 Line Voltage Vdc 24 1 22 to 27 20 to 27 Ss Line Voltage Vac 90 to 240 Vac 120 1 90 to 240 90 to 264 240 2
83. librator Connections Refer to Figure 6 1 and wire the controller according to the procedure given in Table 6 1 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 83 Output Calibration Table 6 1 Set Up Wiring Procedure for Auxiliary Output 1 Apply power and allow the controller to warm up 30 minutes before you calibrate 2 Set LOCK in the Tuning Set Up group to NONE 3 Tag and disconnect the field wiring at the rear of the controller from terminals 12 and 13 See Figure 6 1 4 Connect a milllammeter across these terminals Milliammeter Figure 6 1 Wiring Connections for Calibrating Auxiliary Output 84 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Output Calibration Procedure The procedure for calibrating the auxiliary output is listed in Table 6 2 The numeric codes are also listed Make sure LOCK in the Lock Set Up group is set to NONE see Subsection 3 4 Table 6 2 Auxiliary Output Calibration Procedure an See pees Rem OOO i 1 Enter Calibration setup Upper Display CAL Mode NS Lower Display AUXOUT until you see 2 Calibrate 0 You will see 9 AS Upper Display A Value Lower Display ZROVAL AX or W until the desired 0 output is read on the milliammeter use the values shown below depending on the action of your controller 3 Calibrate 100 To store the 0 value you will see J Upper Display A Value Lower Display SPNVA
84. longer be able to communicate with the instrument via Ethernet until you change the P l E Tool s IP Address setting in the PC COMM SETUP to match the setting that is now in your controller Email Configuration Screen 46 This controller may be configured to support up to two Emails Each Email can be sent to a different address Emails are sent only when the selected alarm transitions from the OFF to the ON state Process iost umant Legkrer Online Configuration Screen Mee to setup tingle parameter Wate baton hai to wende the modiied vaes rto he Orce 2 Aleem 4 Set Pore 1 Tre high PV Alsen 1 Setport 1 har been eege Send Martenarce Persone to check Fow Valve 816 Cej as Figure 3 2 Email Configuration Screen This controller cannot receive Emails so it is suggested that you configure the From Email window with a non Email style address that will make it easy for you to determine which controller sent the Email For Email technical reasons the entry in the From Email window cannot have spaces See Figure 3 2 If you do not know your SMTP IP Address for outgoing Email then contact your Information Technologies IT representative If your PC is on the same LAN that will be used by the controller and which also connects to the Email server then the SMTP IP Address may generally be found by opening a DOS shell and typing ping smtp your domain name and extension i e pin
85. ly display the alarm setpoints and their values Setpoint Values Nuss Their order of appearance is shown below Upper Display the alarm setpoint value Range values are within the range of the selected parameters DE Deviation value within Input 1 Span PV Process variable value Within Input 1 range 3 Change a value To change any alarm setpoint value in the upper display 4 Return to Normal Display 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 57 Operating the Limit Coniroller 4 8 P I E Tool Maintenance Screens Introduction This controller uses special P I E Tool Maintenance Screens which allow remote access and access to functions not accessible via the controller s display and keyboard The figures in this section show screen shots of the Maintenance Screens from the PC version of the P I E Tool Pocket PC Maintenance Screens are generally similar in format but smaller ATTENTION Your instrument may not have all of the screens and parameters shown in this section Loop Data Select Loop Data from the Maintenance Data menu Maintenance Data Status Data Ethernet Status Figure 4 2 Maintenance Data Menu The Loop Data screen allows you to see the current status of the process loop OP1 2 and 3 windows indicate the status of the current outputs If a current output is not installed the OP status for that output is always OK The Alarms and Digit
86. mory integrity If there is a malfunction a diagnostic message will be displayed blinking in the lower display In the case of simultaneous malfunctions the messages will appear in sequence in the lower display Table 7 3 lists these background tests the reason for their failure and how to correct the problem Diagnostic messages may be suppressed stop the blinking by pressing the RUN HOLD key The messages will still be available for viewing by pressing the LOWER DISPLAY key Table 7 3 Background Tests Lower Reason for Failure How to Correct the Problem Display E FAIL Unable to write to non volatile Check the accuracy of the parameter and re memory Anytime you change a parameter and it is not accepted you will see E FAIL enter Try to change something in configuration Run through Read STATUS tests to re write to EEPROM FAILSF This error message shows whenever Run through STATUS check to determine the the controller goes into a failsafe reason for the failure mode of operation This will happen if 2 Press the SET UP key until STATUS appears ae test nn a in the lower display aan aS Press the FUNCTION key to see whether the Calibration test failed test fail th th h th Burnout configured for none Se S E E nan oi E th and the input failed codes a second time to see if the error cleared INIRNG Input 1 out of range The process Make sure the range and actuation are in
87. n De a a h aa ER ER ru 129 vi UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Tables Table 2 1 Condensed Specifications 8 Table 2 2 Limit Relay Contact Information 13 Table 2 3 Alarm Relay Contact Information 13 Table 2 4 Mounting Procedure 15 Table 2 5 Permissible Wiring Bundling 17 Table 2 6 Terminals for connecting a UDC to a MDI Compliant Hub or Switch 23 Table 2 7 Terminals for connecting a UDC directly to a PC utilizing a straight through cable 23 Table 3 1 Configuration Topics 26 Table 3 2 Configuration Prompt Hierarchy 27 Table 3 3 Configuration Procedure 28 Table 3 4 LOCK Group Function Prompts 29 Table 3 5 LIMIT Group Function Prompts 30 Table 3 6 INPUT 1 Group Function Prompts 31 Table 3 7 OPTION Group Function Prompts 35 Table 3 8 Communications Group Function Prompts 37 Table 3 9 ALARMS Group Function Prompts 39 Table 3 10 DISPLY Group Function Prompts 43 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 70 Table 5 2 Equipment Needed 72 Table 5 3 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath 73 Table 5 4 Set Up Wiring Procedure for Thermocouple Inputs using Thermocouple Source 74 Table 5 5 Set Up Wiring Procedure for RTD Inputs 74 Table 5 6 Wiring Connections for Radi
88. n Diagram 25 Figure 3 1 Ethernet Configuration Screen 45 Figure 3 2 Email Configuration Screen 46 Figure 4 1 Operator Interface 50 Figure 4 2 Maintenance Data Menu 58 Figure 4 3 Loop Data Maintenance Screen 59 Figure 4 4 Alarm Details Maintenance Screen 60 Figure 4 5 Digital Input Details Screen 61 Figure 4 6 Status Data Maintenance Screen 62 Figure 4 7 Ethernet Status Maintenance Screen 63 Figure 4 8 IR Communications Address 64 Figure 4 9 Configuration Upload in Progress 65 Figure 4 10 Ethernet Communications Type Selection 66 Figure 4 11 Ethernet Communications Address 67 Figure 4 12 Configuration Upload in Progress 68 Figure 5 1 Input 1 Wiring Terminals 72 Figure 5 2 Wiring Connections for Thermocouple Inputs Using an Ice Bath 73 Figure 5 3 Wiring Connections for Thermocouple Inputs Using Thermocouple Source 74 Figure 5 4 Wiring Connections for RTD Resistance Thermometer Device 74 Figure 5 5 Wiring Connections for Radiamatic Millivolts Volts or Thermocouple Differential Except 0 to 10 Volts 75 Figure 5 6 Wiring Connections for 0 to 10 Volts 76 Figure 5 7 Wiring Connections for 0 to 20 mA or 4 to 20 mA Inputs 77 Figure 6 1 Wiring Connections for Calibrating Auxiliary Output 84 Figure 8 1 UDC2500 Exploded View 101 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual Introduction 1 Introduction 1 1 Overview Function UDC2500 Limit Controllers accept input signals from any of several types of external sensors such as T
89. n shots of the Configuration Screens from the PC version of the P LE Tool Pocket PC Configuration Screens are generally similar in format but smaller Ethernet Configuration Screen 3 07 This controller is shipped from the factory with the IP Address set to 10 0 0 2 the Subnet Mask set to 255 255 255 0 and the Default Gateway set to 0 0 0 0 Consult your Information Technologies IT representative as to how these should be configured for your installation The MAC address is printed on the product label located on the instrument s case These settings can be changed via the Ethernet Configuration Screen as shown in Figure 3 1 See Section 4 9 Configuring your Ethernet Connection for more information Process Instrument Explorer Online Configuration Ve Screen helps to setup single parameter Write button helps to write the modified values into the Device Name Current Value New Value IP Address E VTT ees I 164 145 185 214 Subnet Mask 255 25 nl 25 25 255 0 1 Default Gateway 145 185 164 145 185 1 Communications Alar ms Email Setup Display Maintenance Time Events T Communication Type Ethernet Transmission Status 2 j Process Instrum D EpRS za Figure 3 1 Ethernet Configuration Screen UDC2500 Universal Digital Limit ControllerProduct Manual 45 Configuration WARNING After you change the IP Address you will no
90. nal 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 i I 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual iii 1 1 1 1 2 1 3 2 1 2 2 2 3 2 4 2 5 2 6 2 7 2 8 3 1 3 2 3 3 3 4 3 5 3 6 3 7 3 8 3 9 3 10 3 11 3 12 4 1 4 2 4 3 4 4 4 5 Contents Rue eil enne WEE 1 EMT a RE Eet ENEE 1 LEE Punction of keys ensesine Er RL ER UA 3 Process Instrument Explorer Software 4 CE Conformity Europe sini raten RR ei DH 6 INSTALLATION 2er ee 7 ORE E TEE H Condensed Sp cifications n eseu EE EAR 8 Model Number Interpretation reti iiien leere Deche det RER 11 Limit and Alarm Relay Contact Information cee ceeceecesseeseneeeeeeseeeeecaeceaecsaecnseeseesseeeeeeeees 13 INP OUI EE 14 Wirges nina leat sais es cele gi EIER eae etek R 16 2 6 Electrical Considerations 23 pili ANNERES ee 16 Waring Dita Sans ei ern festen sigtacestelascetbucsauey sensitised EEN OEE ENEA EERE EER 18 Limit Control Application Dagram ne iseni iiei a anaE TS EE EEEE E Ea EES y 25 CONFIGURATION aaas anaana nasaan aneian aaaea aama aaaea aanas aada Wa nawaasa Enia 26 ChuEmIEW seed NEN
91. nal type Refer to Table 5 11 Restore Input Factory Calibration for procedure 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 79 Input Calibration ATTENTION A restored factory calibration overwrites any previous field calibration done for the input and may change the High and Low Range Limits Protect your field calibration from accidental overwrites by configuring the appropriate LOCKOUT selection after calibration See the Section 3 Configuration for specific instructions to set the lockout Table 5 11 Restore Input Factory Calibration an operation Pes Rawk 1 Set LOCKOUT to en until you see NONE NA Upper Display SET UP Lower Display LOCK kd Until you see Sa Upper Display one of the following NONE all parameters are read write CAL all parameters are read write except Calibration CONF configuration parameters are Read Only no writes permitted Lower Display LOCK AX or w Until NONE is in the upper display 2 Enter INPUT 1 seine until you see Setup Group Upper Display SET UP m Lower Display INPUT 1 eunction until you see i Upper Display the current selection cl Lower Display IN1TYP AX or e to change the current selection to another selection 3 Scroll through eunetion until the lower display rolls through the rest of the functions and Functions N returns to Upper Display the new selection Lower Display INxTYP Aor W until you change the input selection in t
92. near actuation is selected at prompt IN1 TYPE FOR EXAMPLE If input 1 is a 4 to 20 mA signal but the signal represents a type K H thermocouple then configure K H and the controller will characterize the 4 to 20 mA signal so that it is treated as a type K thermocouple input high range Parameter definitions are the same as in IN1 TYPE ATTENTION Not available on FM Models we INPUT 1 HIGH RANGE VALUE in 999 to 9999 floating in engineering units is displayed for all inputs engineering units but can only be configured for linear or square root transmitter characterization Scale the 1 input signal to the display value you want for 100 EXAMPLE Process Variable Flow Range of Flow 0 to 250 Liters Minute Actuation Input 1 4 to 20 mA Characterization XMITTER LINEAR Set IN1 HI display value to 250 Set IN1 LO display value to 0 Then 20 mA 250 Liters Minute and 4 mA 0 Liters Minute ATTENTION The range of the Limit setpoint will be limited by the range of units selected here 32 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition IN1 LO 999 to 9999 floating in INPUT 1 LOW RANGE VALUE in engineering units engineering units is displayed for all inputs but can only be configured for linear or square root transmitter characterization Scale the 1 input
93. nections For Rtd Resistance Thermometer Device 74 Wiring Diagrams 18 Wiring The Controller 18 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 131
94. next pages are the identifying codes for the parameters in the various Set up Groups in this instrument Most of the parameters are configurable through the hosts Some are Read Only and are indicated as such and cannot be changed Reading or Writing Do a Read or Write depending on your requirements using the identifying code and format code listed in the tables The range or selection available for each range is listed in the tables 10 4 1 Lock The identifying register addresses listed in Table 10 3 lists all the register addresses and ranges or selections for the function parameters in Set up Group Lock Table 10 3 Set up Group Lock Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal Security Value 00 80 FP R W 0 to 9999 Lockout 0084 132 INT RW 0 None 1 Calibration 2 Configuration 3 Set Point 116 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Modbus Read Write and Override Parameters plus Exception Codes 10 4 2 Limit The identifying register addresses listed in Table 10 4 lists all the register addresses and ranges or selections for the function parameters in Set up Group Limit Table 10 4 Set up Group Limit Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Decimal High Low Limit 0088 136 INT R W 0 Low Limit 1 High Limit Power Up 0089 1
95. ng 17 F G Factory Calibration 79 85 Factory Configuration 100 Failsafe Manual Mode 90 Features 1 Field Calibration 69 Field Wiring 72 File Number 107 111 Filter 33 Floating Point Byte Order 121 Floating Point Parameter Type 105 Frequency 10 Function Code 20 106 Function Code 21 110 Function Codes 20 And 21 104 Function Prompts 27 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 129 Index H High And Low Limit Indication 53 High Limit Controller 1 High Setpoint Limit 30 I J Ice Bath 72 Infrared Communications 5 Infrared Communications 9 Infrared Communications 37 Input 1 Actuation Type 31 Input 1 And Input 2 Wiring Terminals 72 Input 1 Calibration Procedure 78 Input 1 Connections 20 Input 1 High Range Value 32 Input 1 Low Range Value 33 Input 1 Set Up Group 31 Input 1 Set Up Wiring 73 Input Calibration 69 Installation 7 Installation Related Problems 87 Integer Parameter Type 105 IR Port Enable 121 Isolation 9 K Key Error 51 Key Functions 3 Keyboard Failure 97 L Latching Output Relay Failure 96 Limit 117 Limit And Alarm Relay Contact Information 13 Limit Control Application Diagram 25 Limit Controller Wiring 25 Limit Set Up Group 30 Limit Setpoint Setting 55 Line Voltage 10 Line Voltage Wiring 16 Link Length 37 Local Area Network Lan Settings 66 Lock Set Up Group 29 Lockout Feature 51 Lockout Levels
96. nnect UDCs to a LAN rather than using a Hub This is because a Switch passes only those messages for IP addresses that are connected to the Switch while a Hub passes all message traffic Using a Switch thus improves the overall throughput of the traffic to and from the UDCs UDC2500 Universal Digital Limit ControllerProduct Manual 127 Further information 12 Further information 12 1 Modbus RTU Serial Communications Refer to document 51 52 25 66 Modbus RTU Serial Communications User Manual 12 2 Modbus Messaging on TCP IP Refer to document 51 52 25 121 MODBUS Messaging on TCP IP Implementation Guide 12 3How to Apply Digital Instrumentation in Severe Electrical Noise Environments Refer to document 51 52 05 01 How to Apply Digital Instrumentation in Severe Electrical Noise Environments 128 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 A Alarm Blocking 42 Alarm Hysteresis 123 Alarm Outputs 9 Alarm Relay Output Failure 96 Alarm Relays 13 Alarm Setpoints 57 Alarms Set Up Group 39 Ambient Temperature 10 Analog Input Signal Failure Operation 8 Analog Inputs 8 Analog Parameters 114 Annunciators 52 Application Related Problems 88 Auxiliary Output 35 Auxiliary Output Calibration 83 Auxiliary Output Calibration Procedure 85 Auxiliary Output Failure 99 B Background Tests 91 Baud Rate 121 Baud Rate 37 Bias 33 Blocking 123 Burnout Protection 33 Byte Count 106 C C
97. nt 2 000C 012 FP R W Within the range of selected parameter or PV span for deviation alarm 122 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Alarm 1 Setpoint 1 008D 141 INT R W 0 Low Alarm Event 1 High Alarm Alarm 1 Setpoint 2 OO8F 143 INT R W 0 Low Alarm Event 1 High Alarm Alarm 2 Setpoint 1 0091 145 INT R W 0 Low Alarm Event 1 High Alarm Alarm 2 Setpoint 2 0093 147 INT R W 0 Low Alarm Event 1 High Alarm Alarm Hysteresis 0029 041 FP R W 0 0 to 100 of output or span Alarm Latching for 00C8 200 INT R W 0 Non Latching Output 1 1 Latching Alarm States 00C9 201 INT R W State 0 Not in Alarm State 1 In Alarm Bit 0 Alarm 11 State Bit 1 Alarm 12 State Bit 2 Alarm 21 State Bit 3 Alarm 22 State Alarm 1 Blocking 00CA 202 INT R W 0 Disable 1 ALl 2 AL2 3 AL12 Diagnostic Alarm 009A 154 INT R W 0 Disable 1 Alarm 1 2 Alarm 2 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 123 Modbus Read Write and Override Parameters plus Exception Codes 10 4 7 Display Table 10 9 lists all the register addresses and ranges or selections for the function parameters
98. o the next step 3 Select a Function Function Upper Display the current value or selection for the first Parameter N function prompt of the selected Set Up group Lower Display the first Function prompt within that Set Up group Sequentially displays the other function prompts of the Set Up group you have selected Stop at the function prompt that you want to change then proceed to the next step 4 Change the ory Increments or decrements the value or selection that Value or appears for the selected function prompt If you change the Selection value or selection of a parameter while in Set Up mode then decide not to enter it press M A RESET once the original value or selection is recalled 5 Enter the Value Enters value or selection made into memory after another or Selection key is pressed 6 Exit Configuration Exits configuration mode and returns controller to the same state it was in immediately preceding entry into the Set Up mode It stores any changes you have made If you do not press any keys for 30 seconds the controller times out and reverts to the mode and display used prior to entry into Set Up mode 28 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Configuration 3 4 Lock Set Up Group Introduction The Lock Set Up group contains the Function parameters that will allow your controller to protect Configuration and Calibration data Because this group contains functions that have to do with
99. oating point 128 to 215 0080 to 00D7 integer formatted data amp 255 amp OOFF 2 registers IEEE 32 bit floating point Unrestricted Registers As mentioned previously all register data is stored in the EEROM of this instrument with some exceptions These exceptions were made to allow write access to override information The registers which are designated as Override values are listed below These registers do not have restrictions on the number of writes ID Tag Register Number UDC Usage 125 7Dh Computer Setpoint Restrictions on Parameter Numbers in One Message The maximum number of writeable parameters per write request is 1 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 111 Modbus RTU Function Codes 9 4 1 Write Configuration Examples Example 1 112 The following is an example of a request to write the Gain 1 value using Function code 21 15 Hex Request Message Write Gain 1 1 5 ID Tag 1 02 15 OB 06 00 03 00 01 00 02 3F CO 00 00 CRC16 Where 02 Address 15 Function Code 21 15 Hex OB Byte Count 06 Reference Type IEEE Floating Point 00 03 File Number Access Data Value 00 01 Register Address Standard Access Gain 1 ID Tag 1 00 02 Register Count Floating Point Data 3F C0 0000 1 50 CRC16 This is the response to the above request Response Message The response is an echo of the request 02 15 OB 06 00 01 00 02 00 02 3F CO 00 00 CRC16 UDC2
100. oduct Manual 113 Modbus Read Write and Override Parameters plus Exception Codes 114 Analog Parameters e Whenever analog register addresses 0001 through 0074 those that can be changed via communications are changed a Write cycle occurs after receipt of the message and the response is returned Override Parameters e Override analog register address 007D computer setpoint is not stored in non volatile memory It can be changed as frequently as desired with no effect on non volatile memory retentivity but the controller must remain in the slave mode Digital Parameters e Whenever digital configuration register addresses 0080 through OOFA are updated via communications the non volatile memory is updated as soon as the message is received Communications Transfer Rates e Reads minimum 20mS and writes minimum 200mS Supported Function Codes e IR port 20 and 21 e RS485 and Ethernet ports 1 2 3 4 6 16 17 20 21 Communications Modes of Operation e When the Shed Timer is enabled and a write or override occurs the controller will enter Slave Mode The keypad is locked from the operator The purpose of this mode is that if communications is lost and the shed timer times out then the controller will enter a known state of operation The configuration of the Shed Mode and Output and Shed Setpoint Recall are used to configure the controller s shed state While in Slave Mode pushing the MAN AUTO key enters Emergency Manual mode
101. onfiguration the alarm will not activate unless the parameter being monitored has not been in an alarm condition for a minimum of one control cycle 167 ms DIAGAL DIAGNOSTIC WMonitors the Current Output and or Auxiliary Output for an open circuit condition If either of these two outputs falls below about 3 5 mA then an Alarm is activated This configuration is in addition to whatever was selected for AXSxTYPE DIS DISABLE Disables Diagnostic Alarm AL 1 ALARM 1 Alarm 1 is diagnostic alarm AL 2 ALARM 2 Alarm 2 is diagnostic alarm DISWRN DISABLE WARNING Disables Output Fail message on lower display 42 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Configuration 3 10 Display Set Up Group Introduction This group includes selections for Decimal place Units of temperature Language and Power frequency Function Prompts Table 3 10 DISPLY Group Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition DECMAL DECIMAL POINT LOCATION This selection determines where the decimal point appears in the display NONE NONE No Decimal Place fixed no auto ranging ONE ONE 888 8 TWO TWO 88 88 ATTENTION Auto ranging will occur for selections of one or two decimal places For example should the instrument be configured for two decimal places and the PV exceeds 99 99 then the display will change to a single decimal place so that valu
102. ouple E H E Thermocouple High E L E Thermocouple Low J H J Thermocouple High J M J Thermocouple Med J L J Thermocouple Low K H K Thermocouple High K M K Thermocouple Med K L K Thermocouple Low NNMH Ni Ni Moly Thermocouple High NNML Ni Ni Moly Thermocouple Low NICH Nicrosil Nisil Thermocouple High NICL Nicrosil Nisil Thermocouple Low R R Thermocouple S S Thermocouple T H T Thermocouple High T L T Thermocouple Low W H W5W26 Thermocouple High W L W5W26 Thermocouple Low 100H 100 Ohm RTD High 100L 100 Ohm RTD Low 200 200 Ohm RTD 500 500 Ohm RTD RADH Radiamatic RH RADI Radiamatic RI 0 20 0 to 20 Milliamperes 4 20 4 to 20 Milliamperes 10m 0 to 10 Millivolts 50m 0 to 50 Millivolts 100m 0 to 100 Millivolts 0 5 0 to 5 Volts 1 5 1 to 5 Volts 0 10 0 to 10 Volts TDIF Thermocouple Differential PR PR40 PR20 Thermocouple These input types are not available on FM Models 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 31 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition XMITR1 TRANSMITTER CHARACTERIZATION This selection lets you instruct the controller to characterize a linear input to represent a non linear one If characterization is performed by the transmitter itself then select LIN Linear ATTENTION Prompt only appears when a li
103. pgraded to NEMA4X and IP66 Overall Dimensions Max panel thickness Di 19 1 x inches dk 0 35 108 6 92 0 0 8 4 28 0 00 Panel 3 62 0 03 ent 0 00 lt gt 92 0 Se 113 1 0 4 45 3 62 0 03 17 9 0 00 0 70 Figure 2 2 Mounting Dimensions not to scale 14 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Installation 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 Attach screws and washers here for water protection Figure 2 3 Mounting Method Mounting Procedure Table 2 4 Mounting Procedure 1 Mark and cut out the controller hole in the panel according to the dimension information in Figure 2 2 2 Orient the case properly and slide it through the panel hole from the front 3 Remove the mounting kit from the shipping container and install the kit as follows e 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 Figure 2 3 e 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 Figure 2 3 e Tighten
104. put is outside the range limits configured properly Check the input source Restore the factory calibration See Subsection 5 6 Field calibrate See Section 5 Input Calibration IN EL Two consecutive failures of input 1 Make sure the actuation is configured integration i e cannot make analog correctly See Section 3 Configuration to digital conversion This will happen 2 Make sure the input is correct and that it has if ee not burned out opened e Upscale or Downscale i Burnout is selected and th 1 Check for gross over ranging with a multimeter input is open d Input not configured correctly Restore factory calibration See Subsection for the sensor being used 5 6 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 91 Troubleshooting Service Lower Display Reason for Failure How to Correct the Problem PV LIM PV out of range PV INP1 x RATIO1 INP1 BIAS 1 Make sure the input signal is correct 2 Make sure the Ratio and Bias settings are correct 3 Recheck the calibration Use Bias of 0 0 TCWARN The Thermocouple is starting to burnout This is a warning message that the controller has detected that the thermocouple is starting to burnout This error message may also be created if the resistance of the wires used to connect the thermocouple to the instrument are above 100 ohms TCFAIL The Thermocouple is in imminent danger of burning out Thi
105. puter should not be transmitting on the link while the loopback test is active The instrument does not have to be 38 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Configuration 3 9 Alarms Set Up Group Introduction An alarm is an indication that an event that you have configured for example Process Variable has exceeded one or more alarm limits There are two alarms available Each alarm has two setpoints You can configure each of these two setpoints to alarm on various controller parameters There are two alarm output selections High and Low You can configure each setpoint to alarm either High or Low These are called single alarms You can also configure the two setpoints to alarm on the same event and to alarm both high and low A single adjustable Hysteresis of 0 to 100 is configurable for the alarm setpoint See Table 2 3 in the Installation section for Alarm relay contact information The prompts for the Alarm Outputs appear whether or not the alarm relays are physically present This allows the Alarm status to be shown on the display and or sent via communications to a host computer Function Prompts Table 3 9 ALARMS Group Function Prompts Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition A1S1TY ALARM 1 SETPOINT 1 TYPE Select what you want Setpoint 1 of Alarm 1 to represent It can represent the Process Variable Deviation Input 1 Input 2
106. query without a communication error but cannot handle it i e request is to a non existent coil or register The slave will return with an exception response informing the master of the nature of the error Illegal Data Address The exception response message has two fields that differentiate it from a normal response Function Code Field In a normal response the slave echoes the function code of the original query in the function code field of the response All function codes have a most significant bit MSB of 0 their values are below 80 hex In an exception response the slave sets the MSB of the function code to 1 This makes the function code value in an exception response exactly 80 hex higher than the value would be for a normal response With the function code s MSB set the master s application program can recognize the exception response and can examine the data field for the exception code Data Field In a normal response the slave may return data or statistics in the data field In an exception response the slave returns an exception code in the data field This defines the slave condition that caused the exception 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 125 Modbus Read Write and Override Parameters plus Exception Codes Query Example Internal slave error reading 2 registers starting at address 1820h from slave at slave address 02 02 03 18 20 00 02 CRC CRC Response Example
107. r interface as shown in Figure 4 1 let you see what is happening to your process and how the Limit Controller is responding The Limit Controller can be either a single line display device except when in the SETUP mode or the LOWER DISPLAY key is pressed or limit has been reached or it can be a dual line display device upper display shows PV and lower display shows SP This display can be one of two types Single Display Mode 1 The PV is displayed in the upper display and the lower display is blank Single Display Mode 2 The setpoint is displayed in the upper display and SP is displayed in the lower display Viewing the operating parameters Press the LOWER DISPLAY key to scroll through the operating parameters SP Setpoint PV Process Variable You can press or to change the value of this parameter Timing out from lower display The normal variable display will automatically return in the upper display if the LOWER DISPLAY key is not pressed for 30 seconds 52 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Operating the Limit Controller Diagnostic Error Messages The UDC2500 performs background tests to verify data and memory integrity If there is a malfunction an error message will be displayed In the case of more than one simultaneous malfunction the messages will be displayed sequentially on the lower display If any of these error messages in Table 4 3 occur refer to Section 7 Troubleshooting
108. range values from Table 5 1 Use these values when calibrating your controller Table 5 1 Voltage Milliamp and Resistance Equivalents for Input 1 Range Values Sensor Type PV Input Range Range Values Thermocouples per ITS 90 B 0 to 3300 18 to 1816 0 100 mV 13 769 mV E 454 to 1832 270 to 1000 9 835 mV 76 373 mV E low 200 to 1100 129 to 593 6 472 mV 44 455 mV J 0 to 1600 18 to 871 0 886 mV 50 060 mV J med 20 to 900 7 to 482 0 334 mV 26 400 mV J low 20 to 550 7 to 288 0 334 mV 15 650 mV K Oto 2400 18 to 1316 0 692 mV 52 952 mV K med 20 to 1200 29 to 649 1 114 mV 26 978 mV K low 20 to 750 29 to 399 1 114 mV 16 350 mV NiMo NiCo NM90 32 to 2500 0 to1371 0 000 mV 71 773 mV NM90 low 32 to 1260 0 to 682 0 000 mV 31 825 mV Nicrosil Nisil Nic 0 to 2372 18 t01300 0 461 mV 47 513 mV Nic low 0 to 1472 18 to 800 0 461 mV 28 455 mV R 0 to 3100 18 t01704 0 090 mV 20 281 mV 70 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Input Calibration Sensor Type PV Input Range Range Values S 0 to 3100 18 t01704 0 092 mV 17 998 mV T 300 to 700 184 to 371 5 341 mV 19 097 mV T low 200 to 500 129 to 260 4 149 mV 12 574 mV W5W26 0 to 4200 18 to 2315 0 234 mV 37 075 mV W5W26 low 0 to 2240 18 to 1227 0 234 mV 22 283 mV RP20 RP40 32 to 3216 0 to1880 0 000 mV 4 933 mV Thermocouple 50 to 150
109. rds Controller Keyboard or specific keys may be LOCKED OUT via the security code Run the keyboard test Replace the display keyboard if any keys are shorted out Withdraw the chassis from the case and visually inspect the connection Use your four digit security code number to change the lockout level Refer to Section 3 Configuration Press the SET UP key and hold in then press the FUNCTION key at the same time The controller will run a display test Then you will see Upper Display KEYS Lower Display TRY ALL Press each key If it works the key name will appear in the lower display Refer to Parts Replacement Procedures in this section 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 97 Troubleshooting Service Procedure 5 Table 7 8 explains how to troubleshoot a Communications failure Table 7 9 Troubleshooting a RS 485 Communications Failure Step What to do How to do it 1 Check the field wiring and Using an ohm meter check the resistance across termination resistor the communications rear terminals See Section 2 7 for wiring diagrams 2 Make sure the Communications Withdraw the chassis from the case and inspect the Printed Wiring Board is installed board See the exploded view Figure 8 1 for properly in the controller location of the board Return the chassis to the case 3 Determine if the Communications Disconnect the communications cable from the rear bo
110. reate configurations with intuitive software program running on either a Pocket PC a Desktop or a laptop computer e Create edit configurations live just connect software to controller via comm port e Create edit configurations offline and download to controller later via comm port e Port types available on every UDC2500 o infrared o RS485 o Ethernet e Same port types on UDC3200 and UDC3500 allow interconnectivity e This software is available in English Spanish Italian German and French d 12 28 GN Communication Setup Upload Offline Download Configuration sie E em Online Maintenance Configuration Data Infrared Iden Figure 1 2 Screen capture of Process Instrument Explorer running on a Pocket PC 4 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Introduction Infrared communications The infrared connection provides a non intrusive wireless connection with the instrument and maintains NEMA4X AND IP66 integrity 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 s
111. s Refer to Figure 5 4 and wire the controller according to the procedure given in Table 5 5 Table 5 5 Set Up Wiring Procedure for RTD Inputs 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 4 Decade CS 25R Resistance a Rj 26 Box G i 27 Copper Leads Equal Length Figure 5 4 Wiring Connections for RTD Resistance Thermometer Device 74 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Input Calibration Radiamatic Millivolts Volts or Thermocouple Differential Inputs Refer to Figure 5 5 and wire the controller according to the procedure given in Table 5 6 Table 5 6 Wiring Connections for Radiamatic Thermocouple Differential Millivolts or Volts Except 0 to 10 Volts 1 Connect the copper leads from the calibrator to the Input 1 terminals as shown in Figure 5 5 2 Place current voltage source at zero before switching on 3 Do not switch current voltage source ON OFF while connected to the instrument ATTENTION For Radiamatic inputs only set Emissivity value to 1 0 See Subsection 3 6 Configuration Set Up prompt INPUT1 function prompt EMISS Millivolt or Volt Source Figure 5 5 Wiring Connections for Radiamatic Millivolts Volts or Thermocouple Differential Except 0 to 10 Volts Table 5 7 Procedure to determine calibration voltages for Thermocouple Differential input types other than the Factory Setting 1 Obtain a copy of the ITS 90 Standard
112. s is a warning message that the controller has detected that the thermocouple will soon fail User should consider replacing the thermocouple as soon as possible OUT2FL Auxiliary Output is less than 3 5 mA The auxiliary output is open circuit Check the field wiring See Procedure 9 92 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Troubleshooting Service 7 6 Controller Failure Symptoms Introduction In addition to the error message prompts there are failure symptoms that can be identified by noting how the controller displays and indicators are reacting Symptoms Compare your symptoms with those shown in Table 7 4 Table 7 4 Controller Failure Symptoms Upper Lower Indicators Controller Probable Trouble Display Display Output Cause shooting Procedure Upper Lower Indicators Controller Probable Trouble Display Display Output Cause shooting Procedure Blank Blank Off None Power Failure 1 Displayed Controller Relay Output Output Output disagrees with disagrees with controller output displayed output External Alarm Malfunction in function does alarm output not operate properly Display does not change when a key is pressed Keyboard 4 Malfunction Controller fails to go into Slave operation during communications Communications 5 Failure OK Displayed OK Controller Auxiliary Output 6 Output Auxiliary Output disagrees with disagrees Auxiliary
113. sal Digital Limit ControllerProduct Manual 3 07 Modbus Read Write and Override Parameters plus Exception Codes Parameter Register Data Access Data Range or Description Address Type Enumerated Selection Hex Decimal Input 1 00A9 169 INT R W 0 BTC Transmitter Characterization 1 ETCH 2 ETCL 3 JTCH 4 JTCM S5 JTCL 6 KTCH 7 KTCM 8 KTCL 9 NNMH 10 NNML 11 Nicrosil H TC 12 Nicrosil L TC 13 RTC 14 STC 15 TTCH 16 TTCL 17 WTCH 18 WTCL 19 100 PT RTD 20 100 PT LORTD 21 200 PT RTD 22 500 PT RTD 23 Radiamatic RH 24 Radiamatic RI 25 Linear 26 Square Root Input 1 High 001D 029 FP R W 999 to 9999 Engineering Range Value Units Linear types only Input 1 Low OO1E 030 FP R W 999 to 9999 Engineering Range Value Units Linear types only Input 1 Ratio 006A 106 FP R W 10 00 to 10 00 Input 1 Bias 0069 105 FP R W 10 to 10 Input 1 Filter 002A 042 FP R W 0 to 120 seconds Burnout Open 0085 133 INT R 0 Downscale Circuit 1 Upscale Detection Emissivity 0017 023 FP R W 0 01 to 1 00 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 119 Modbus Read Write and Override Parameters plus Exception Codes 10 4 4 Options Table 10 7 lists all the register addresses and ranges or selections for the function parameters in Set up Group Options Table 10 6 Set up Group Options Parameter Re
114. screws to 2 Ib inch 22 Necm to secure the case against the panel CAUTION Over tightening will cause distortion and the unit may not seal properly 4 For water protected installations install four screws with washers into the four recessed areas in the corners of the bezel Figure 2 3 Push the point of the screw through the center piercing the elastomeric material and then tighten screws to 5 Ib in 56 Necm 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 15 Installation 2 6 Wiring 2 6 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 s
115. signal to the display value you want for 0 See example above ATTENTION The control setpoint for Input 1 will be limited by the range of units selected here 999 to 9999 floating in BIAS ON INPUT 1 Bias is used to engineering units for Non FM compensate the input for drift of an input Models value due to deterioration of a sensor or S some other cause Select the bias value you 10 to 10 floating in engineering want on Input 1 units for FM Models FILTR1 0 to 120 seconds FILTER FOR INPUT 1 A software digital 0 No Filter filter is provided for Input 1 to smooth the input signal You can configure the first order lag time constant from 1 to 120 seconds If you do not want filtering enter 0 BRNOUT BURNOUT PROTECTION SENSOR BREAK provides most input types with upscale or downscale protection if the input fails UP UPSCALE BURNOUT will force the Input 1 signal to the full scale value when the sensor fails Diagnostic message IN1 FAIL intermittently flashed on the lower display The controller remains in Automatic control mode and adjusts the controller output signal in response to the full scale Input 1 signal developed by the Burnout circuitry DOWN DOWNSCALE BURNOUT will force the Input 1 signal to the lower range value when the sensor fails Diagnostic message IN1 FAIL intermittently flashed on the lower display ATTENTION For Burnout to function properly on a 0 20 mA input type or a
116. ted linearly to 0 5 Amp at 55 C Customer should size fuse accordingly Use Fast Blo fuses only Gi Electromechanical relays are rated at 5 Amps 120 Vac or 30 Vdc and 2 5 Amps at 240 Vac Customer should size fuses accordingly Use Fast Blo fuses only XXXXX Figure 2 8 Solid State Relay Output 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 21 Installation Time Simplex Customer Supplied Electromechanical relay SI W Gei JE Customer Supplied Load 0 Solid State relay Supply Power o lt ews Load Se Supply Power o lt To terminal E 7or9 CAUTION Open collector outputs are internally powered at 30 Vdc Connecting an external power supply will damage the controller Electromechanical relays are rated at 5 Amps 120 Vac or 30 Vdc and 2 5 Amps at 240 Vac Customer should size fuses accordingly Use Fast Blo fuses only XXXX Figure 2 9 Open Collector Output COMMUNICATION MASTER D B SHLD D A 120 OHMS Connect shield to ground at one end only TO OTHER COMMUNICATION CONTROLLERS 120 OHMS ON LAST LEG Do not run the communications lines in the same conduit as AC power Use shielded twisted pair cables Belden 9271 Twinax or equivalent XXXX Figure 2 10 RS 422 485 Communications Option Connections 22 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07
117. the RESET key or Contact Input Option 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 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 1 Introduction 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 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 an
118. the controller has External Reset enabled To allow External Reset contact input use the procedure in Table 4 4 Table 4 4 Using Contact Input Option sem onion ren 1 Select Options Set up Group 2 Access the External Reset Prompt 3 Change a value es Ge A Or y Until you see Upper Display SET Lower Display OPTIONS Until you see Upper Display ENAB DIS Lower Display DIGIN1 To select ENAB in the upper display 56 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Operating the Limit Coniroller 4 7 Alarm Setpoints Introduction An alarm consists of a relay contact and an operator interface indication The alarm relay is de energized if setpoint 1 or setpoint 2 is exceeded The alarm relay is energized when the monitored value goes into the allowed region by more than the hysteresis The relay contacts can be wired for normally open NO energized or normally closed NC de energized using internal jumper placement See Table 2 3 in the Section 2 Installation for alarm relay contact information There are four alarm setpoints two for each alarm The type and state High or Low is selected during configuration See Subsection 3 Configuration for details Alarm Setpoints Display Table 4 5 Procedure for Displaying Alarm Setpoints le Tre mn Select Alarm i Until you see Set up Group NEA Upper Display SET Lower Display ALARMS 2 Access the Alarm Function To successive
119. the controller is rated at NEMA4X and IP66 when properly installed Installation Category Overvoltage Category Category I 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 prot
120. tion normally at power up that is no reset of the latching relay is required unless a limit has been exceeded If the limit was latched when power went down the unit will be in limit at power up Refer to Section 3 Configuration subsection 3 4 Limit Parameters Set Up Group under SET UP prompt LIMIT and make your selection at FUNCTION prompt POWRUP 54 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 How to set a limit setpoint Operating the Limit Coniroller Step Operation Press Result 1 Display Press the Lower Display key till SP appears setpoint 2 Enter the Limit Aorw Set the SP using the Up amp Down arrow keys to the desired Limit Setpoint Setpoint 3 Store the limit Press the Lower Display to store the value setpoint 4 If the display Press the Auto Man Reset key flashes Limit 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 55 Operating the Limit Coniroller How to Reset the Latching Relay The latching relay cannot be reset until the PV input signal drops below the high set point High Limit or rises above the low set point Low Limit value Press the M A RESET key or make contact closure of an external switch if the External Reset option is present Using the Digital Input Option External Reset The Contact Input option detects the state of external contacts On contact closure the controller will reset the latching relay if
121. troller e Place current source at zero before switching ON e Do not switch current sources OFF ON while connected to the UDC2500 input 72 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Input Calibration 5 4 Input 1 Set Up Wiring Thermocouple Inputs Using an Ice Bath Refer to Figure 5 2 and wire the controller according to the procedure given in Table 5 3 Table 5 3 Set Up Wiring Procedure for Thermocouple Inputs Using an Ice Bath 1 Connect the copper leads to the calibrator 2 Connect a length of thermocouple extension wire to the end of each copper lead and insert the junction points into the ice bath 3 Connect the thermocouple extension wires to the terminals for Input 1 See Figure 5 2 Millivolt Source Ice Bath Copper Leads Thermocouple Extension Wire Figure 5 2 Wiring Connections for Thermocouple Inputs Using an Ice Bath 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 73 Input Calibration Thermocouple Inputs Using a Thermocouple Source Refer to Figure 5 3 and wire the controller according to the procedure given in Table 5 4 Table 5 4 Set Up Wiring Procedure for Thermocouple Inputs using Thermocouple Source 1 Connect the thermocouple extension wires to the terminals for Input 1 as shown in Figure 5 3 Thermocouple Source Thermocouple Extension Wire Figure 5 3 Wiring Connections for Thermocouple Inputs Using Thermocouple Source RTD Input
122. ts One 30 Vdc source for external dry contacts or isolated solid state contacts Digital Inputs are Optional isolated from line power earth ground analog inputs and all outputs except for the Second Current Output 8 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Installation Controller Output Types Electromechanical Relay SPDT contacts Both Normally Open and Normally Closed contacts are brought out to the rear terminals Internally socketed Resistive Load 5 amps 120 Vac or 240 Vac or 30 Vdc Inductive Load coso 0 4 3 amps 130 Vac or 250 Vac Inductive Load L R 7 msec 3 5 amps 30 Vdc Motor 1 6 H P Solid State Relay Zero crossing type SPST solid state contacts consisting of a triac N O output Internally socketed Resistive Load 1 0 amp 25 C and 120 or 240 Vac 0 5 amp 55 C and 120 or 240 Vac Inductive Load 50 VA 120 Vac or 240 Vac Minimum Load 20 milliamps Open Collector Outputs One or Two Socketed assembly replacing a relay Opto isolated from all other circuits except current output and not from each other Internally powered 30 Vdc Note Applying an external power supply to this output will damage the instrument Maximum Sink Current 20 mA Short circuit current limit 100 mA Alarm Outputs Optional One or two SPDT Electromechanical relays Up to four setpoints are independently set as high or low alarm two for each relay Setpoint can be on Process V
123. ts affected by these selections 4mA VAL and 20mA VAL AATTENTION Output cannot be configured when Three Position Step Control is used NONE NO AUXILIARY OUTPUT PROC PROCESS VARIABLE Represents the value of the Process Variable PV Input XxRatioX BiasX DEV DEVIATION PROCESS VARIABLE MINUS SETPOINT Represents 100 to 100 of the selected PV span in engineering units Zero deviation will produce a center scale 12 mA or 50 output A negative deviation equal in magnitude to the Auxiliary Output High Scaling Factor will produce a low end output 4 mA or 0 output A positive deviation equal in magnitude to the Auxiliary Output Low Scaling Factor will produce a high end output 20 mA or 100 FOR EXAMPLE Input 1 Type T High Thermocouple PV range 300 F to 700 F PV span 1000 F Deviation Range 1000 F to 1000 F Auxiliary Output Low Scale Value 0 0 Auxiliary Output High Scale Value 1000 lf PV 500 F and SP 650 F then Deviation Display 150 F which is 7 5 of the Deviation Range so Auxiliary Output 50 7 5 42 5 3 07 UDC2500 Universal Digital Limit ControllerProduct Manual 35 Configuration Function Prompt Selection or Range of Setting Parameter Lower Display Upper Display Definition FACTOR Use a value in engineering units to represent all AUX OUT parameters except output Use value in percent for output Output can be between 5
124. ut 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 Figure 2 6 Input 1 Connections XXXX UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Installation ae L1 Reay Ee 21 Relay Load OG gr o terminal o o Power Q 19 or 21 Alarm Load oe vo Relay 2 23 Relay Load Supply Power o To terminal Ki 4or6 Load _5 Relay Load Supply Power a Ga To ile Electromechanical relays are rated at Amps 120 Vac or 30 Vdc and 2 5 Amps at 240 Vac Customer should size fuses accordingly Use Fast Blo fuses only XXXX Alarm N O Relay 1 26 Figure 2 7 Electromechanical Relay Output Output Load L1 Relay 1 o Supply Power Load Relay Load Supply Power o To terminal 4or6 Load oc Relay Load Supply Power a To terminal 7or9 O If the load current is less than the minimum rated value of 20 mA then there may be residual voltage across both ends 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 Solid State relays are rated at 1 Amp at 25 C and dera
125. ut signal equal to the 100 range value for your particular input sensor See Table 5 1 for Voltage Degrees or Resistance equivalents for 100 range values e Wait 15 seconds and If Then you are calibrating a Thermocouple input go to step 4 you are calibrating other than a go to step 5 Thermocouple input 4 Check the Cold Function The calculations for zero and span are now stored and you Junction N 4 will see Temperate Upper Display The cold junction temperature at the rear terminals Lower Display CJTEMP The value in the upper display is in tenths of a degree It is the current reading of the temperature as measured at the thermocouple terminals and recognized by the controller You can change this value if it is in error using the or V keys WARNING The accuracy of the controller is directly affected by the accuracy of this value It is recommended that this value not be changed under normal circumstances 5 Exit the The controller stores the calibration constants and exits the Calibration Mode calibration mode 5 6 Restore Input Factory Calibration Introduction The factory calibration constants for all the input actuation types that can be used with the controller are stored in its non volatile memory Thus you can quickly restore the Factory Calibration for a given input actuation type by simply changing the actuation type to another type and then changing it back to the origi
126. utput PWA 30756725 501 e Solid State Relay Table 8 2 Parts Not Shown 30731996 506 4 20 mA Input Resistor Assembly 250 ohm 30754465 501 0 10 Volt Input Resistor Assembly 100K pair 51452763 501 Mounting Kits 12 brackets 102 UDC2500 Universal Digital Limit ControllerProduct Manual 3 07 Parts List 8 2 Removing the chassis 3 07 Insert thin screwdriver under tabs and twist slightly and gently to disengage front Using a thin screwdriver gently twist the screwdriver to pry the side tabs from the front face Pry just enough to release it otherwise you ll bend or break the tab If you break or bend the tab and can t reattach the front snugly you ll need to reattach the front using the 4 NEMA4 screws provided See Figure 2 3 on page 15 UDC2500 Universal Digital Limit ControllerProduct Manual 103 Modbus RTU Function Codes 9 Modbus RTU Function Codes 9 1 Overview This section describes the function codes needed to upload and download the configuration from a host computer into this instrument What s in this section The following topics are covered in this section 9 1 Overview 104 9 2 General Information 104 9 3 Function Code 20 106 9 4 Function Code 21 9 2 General Information This instrument uses a subset of the standard Modbus RTU function codes to provide access to process related information Several MODICON function codes are implemented It is appropriate to define instrument speci

Download Pdf Manuals

image

Related Search

Related Contents

Global Search v.2.8 for Microsoft Dynamics CRM 4.0  CDA VM450  Fahrrad-BenutzerhandBuch    Liebherr KBES4260  Descargar PDF - Sabo Española  Users Manual, Fluke 87 - UCSD Department of Physics  Funciones de la proyección  MANUAL HK SL9 WR 20NOV12.indd  Dirt Devil Factory M3320  

Copyright © All rights reserved.
Failed to retrieve file