Uec 3 & Uec3 Mpc Manual440-12100

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UEC-3 &UEC-3-MPC

Bulletin 440-12100 6/96

Installation & Commissioning Manual

Limitorque ®



UEC-3 & UEC-3-MPC Installation & Commissioning Manual ©1996 Copyright Limitorque Corporation, All rights reserved.

Printed in the United States of America.

Disclaimer

All rights reserved. No part of this book shall be reproduced, stored in a retrievalsystem, or transmitted by any means, electronic, mechanical, photocopying,

recording, or otherwise without the written permission from Limitorque.While

every precaution has been taken in the preparation of the book, the publisher

assumes no responsibility for errors or omissions. Neither is any liability

assumed for damages resulting from the use of the information contained

herein.

This document is proprietary information of Limitorque Corporation furnished

for customer use ONLY. No other uses are authorized without written permis-

sion of Limitorque Corporation.

Limitorque Corporation reserves the right to make changes, without notice, tothis document and the products it describes. Limitorque Corporation shall not

be liable for technical or editorial errors or omissions made herein; nor for inci-

dental or consequential damages resulting from the furnishing, performance

or use of this document.

This manual contains information that is correct to the best of Limitorque’s

knowledge. It is intended to be a guide and should not be considered as a sole

source of technical instruction, replacing good technical judgment, since all

possible situations cannot be anticipated. If there is any doubt as to exact

installation, configuration, and/or use, call Limitorque Corporation‚ at (804)

528-4400.

The choice of system components is the responsibility of the buyer, and the

use to which they are put cannot be the liability of Limitorque Corporation.

However, Limitorque’s sales team and application engineers are always avail-

able to assist you in making your decision.

AcknowledgmentsSections of this document are edited and/or reprinted with the written per-

mission of A.E.G. Modicon Inc and Allen-Bradley‚ a Rockwell International

Company.

LOGITORQUE® and LIMITORQUE® are registered trademarks of Limitorque Corporation

Modbus® is a registered trademarks of A.E.G. Modicon, Inc

BITBUS® is a registered trademark of Intel Corporation

MS-DOS® is a registered trademark of Microsoft Corporation

IBM-PC is a registered trademark of International Business Machines Corporation

Belden® is a registered trademark of Belden, a division of Cooper Industries, Inc.

Limitorque Corporation UEC-3 & UEC-3-MPC Installation & Commissioning Manual

Bulletin 440-12100 6/96

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Contents

1. Introduction 1

1.1 Premise............................................................................................................................................11.2 Emphasis .........................................................................................................................................1

1.3 Audience ..........................................................................................................................................2

2. Product Description 32.1 UEC-3...............................................................................................................................................3

2.2 UEC-3-MPC.....................................................................................................................................3

3. General Information/Workmanship 53.1 Safety Information............................................................................................................................5

3.2 Electrostatic Discharge Awareness................................................................................................5

3.3 UEC-3 Label ....................................................................................................................................6

3.4 Dip Switch Location and Conventions ...........................................................................................73.5 EPROM Care and Installation ........................................................................................................9

3.5.1 Care and Storage...........................................................................................................9

3.5.2 Removal........................................................................................................................10

3.5.3 Installation.....................................................................................................................10

3.6 Supply Voltage...............................................................................................................................10

4. UEC-3/UEC-3-MPC Installation 134.1 Site preparation .............................................................................................................................13

4.2 Visual inspection ...........................................................................................................................13

4.3 Wire preparation............................................................................................................................13

4.4 Actuator Wiring ..............................................................................................................................13

4.5 Grounding ......................................................................................................................................14

5. UEC-3/UEC-3-MPC Commissioning 155.1 Initial inspection .............................................................................................................................15

5.2 Start-up procedure ........................................................................................................................15

5.2.1 Power LEDs .................................................................................................................17

5.2.2 Reset LEDs..................................................................................................................17

5.3 UEC-3-MPC Calibration Procedure .............................................................................................18

5.4 Troubleshooting..............................................................................................................................23

5.4.1 Troubleshooting Tools ..................................................................................................23

5.4.1.1 Universal Diagnostic Tool...........................................................................23

5.4.1.2 Modsim Diagnostic Software.....................................................................23

5.4.2 Component Replacement ...........................................................................................24

5.4.2.1 Control Fuse Replacement........................................................................24

5.4.2.2 24VDC I/O Power Supply Fuse Replacement ........................................25

Limitorque Corporation UEC-3 & UEC-3-MPC Installation & Commissioning Manua

Bulletin 440-12100 6/96



5.4.2.3 Single Board Computer Replacement......................................................26

5.4.2.4 Termination/Interconnect Board Replacement .........................................27

5.4.3 Complete Module Replacement .................................................................................28

6. Conversion of UEC-3 Basic Controller 31

6.1 Converting UEC-3 to UEC-3-MPC Position Controller...............................................................316.1.1 Installation of PT20SD (optional) ................................................................................32

7. Parts 33

8. Customer Service 35

Figures3-1 Model, Option, and Configuration Identification Label..................................................................6

3-2 Single Board Computer DIP Switch and Component Location ...................................................7

3-3 DIP Switch Conventions .................................................................................................................8

3-4 Default DIP Switch Settings for UEC-3 and UEC-3-MPC ............................................................93-5 Locating Power Supply Board .....................................................................................................11

3-6 Locating Power Supply Board Mounting Screw..........................................................................11

3-7 Locating Power Supply Bracket Retaining Screw.......................................................................12

3-8 Power Supply Board .....................................................................................................................12

5-1 UEC-3/UEC-3-MPC Start-up Procedure.....................................................................................16

5-2 UEC-3-MPC Calibration Procedure........................................................................................18-21

Tables5-1 Table of Values for Proportional Band and Deadband................................................................22


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iii



1. Introduction

1.1 Premise

These instructions are to aid in the installation and commissioning of the UEC-

3 family of control modules. Your safety and satisfaction are important to

Limitorque. Be sure to follow all instructions carefully. Pay special attention to

safety.

1.2 Emphasis

Please refer to the following methods used to emphasize text throughout this

manual:

• Safety warnings, cautions, and notes present material that is important to

user safety. Be sure to read any safety notices you see as they could preventequipment damage, personal injury, or even death to you or a co-worker.

• “Warning” refers to personal safety. They alert you to potential danger or

harm. Failure to follow warning notices could result in personal injury or death.

• “Caution” directs attention to general precautions, which if not followed, could

result in personal injury and/or equipment damage.

• “Note” highlights information critical to your understanding or use of these

products.

• Bold text highlights other important information that is critical to system com-

ponents.

• CAPITALIZED text stresses attention to the details of the procedure.

• Underlined text emphasizes crucial words in sentences that could be mis-

understood if the word is not recognized.

The purpose of this section is to alert you to possible safety hazards associ-

ated with this equipment and the precautions you can take to reduce the risk

of personal injury and damage to the equipment.

Safety notices in this manual provide important information. Read and be famil-

iar with these instructions before attempting installation, operation, or

maintenance. Failure to observe these precautions could result in serious

bodily injury, damage to the equipment, or operational difficulty.


Bulletin 440-12100 6/96



1.3 Audience

This Installation and Commissioning Manual is designed to help you to prop-

erly install and commission the UEC-3 Control Module and the UEC-3

Modulating Position Controller.You do not have to be an expert in electronics

or digital controls to utilize this manual. However, this manual assumes youhave a working understanding of basic electronics and a fundamental under-

standing of microprocessor concepts.

The material in this manual supplements the following Limitorque publication:

UEC-3 Operation Manual - Bulletin 440-12000 Rev. A.

It is recommended that you completely read all the general information and

all sections pertaining to the type of UEC-3 module for your application so that

you can promptly find any information you need.

It is also recommended that you have a copy of the Operation Manual for your

UEC-3 module as well as the applicable actuator wiring diagram availablebefore attempting to install or commission a UEC-3 or UEC-3-MPC controlled

actuator.


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2. Product Description

The UEC-3 is a microprocessor based controller for the complete range of

Limitorque actuators. It provides many protection and control features whichare designed to be individually configured to fit specific customer needs.This

configuration may be altered in the field as process requirements change or

as the real needs of the actuator are realized.

2.1 UEC-3

(Universal Electronic Controller)

The basic UEC-3 model provides control, indication, alarm, and protection

features. It is intended for use with open/close or pushbutton throttling valves.

2.2 UEC-3-MPC(Modulating Position Controller)

This model is designed to position valves in accordance with a 4-20mA

command signal, thereby controlling level, flow, pressure, etc. All the indica-

tion, alarm, and protection features of the basic UEC-3 are retained in this

model.


Bulletin 440-12100 6/96



This page is intentionally blank.


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3. General Information/Workmanship

Throughout this manual, the designation “UEC-3” will refer to a basic Universal

Electronic Controller with a 4-wire configuration. UEC-3-MPC will refer to theUniversal Electronic Controller with positioning control.

The information in this section is applicable to all members of the UEC-3 family

of controllers.

3.1 Safety Information

Practice all plant and safety codes and standards. Failure to follow instructions

can result in personal injury and/or property damage.

To prevent the possible ignition of hazardous atmospheres, do NOT remove

the cover of Division 1 units with power applied.

All servicing should be performed by qualified technicians. Dangerous volt-

ages may be present on the circuit boards and terminations.

Use extreme caution when working around power-input cables.These cables

have potentially lethal voltages on them.

When fuse replacement is required, use only Limitorque specified parts for

continued safe operation.

Have qualified personnel verify all wiring and connections against vendor draw-

ings prior to energizing the equipment. Incorrect wiring and/or connections

can result in equipment damage.

3.2 Electrostatic Discharge Awareness

The circuit boards in the UEC products may contain components that are

subject to damage from electrostatic discharge (static electricity).The follow-

ing precautions and procedures are recommended when handling circuit

boards or components.Failure to observe these practices when handling and

shipping circuit board products may void your warranty.

Keep plastics and other materials prone to the buildup of electrostatic charges

(static electricity) away from boards, components, and work area.

Avoid synthetic or wool clothing and wear cotton or cotton blend materials.

Keep components and circuit boards away from clothing and hair.

Discharge static electricity on your body by touching and momentarily holding

a grounded metal object before handling electronic components.This is espe-


Bulletin 440-12100 6/96



cially important after walking across carpeted areas.

Handle components in the field as little as necessary.

Handle components only by the edges, and avoid contact with leads, circuits,

or connectors.

Do not touch the printed circuit board, the connectors, or the components with

conductive devices or with your hands.

Always place the component or board into an anti-static protective bag for

transportation or storage.

Transport all static-sensitive components only in static-shielding carriers or

packages. Place static awareness labels on all components to prevent removal

from static-shielding container during transit.

Handle all static-sensitive components at a static-safe work area including:floor mat, wrist strap, air ionizer, ground cord, and conductive table mat.

Do not subject components to sliding movements over any surface, at any

time.

3.3 UEC-3 Labels

Labels are affixed to the housings of all UEC modules.The information included

on this label indicates: type of UEC-3 (basic, MPC or DDC), options, trans-

former voltage, module serial number and status of LK1 link. The label also

contains space for the user to record the settings of the configuration DIP

switches. See Figure 3-1

Figure 3-1 - Model, Option, and Configuration Identification Label


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6

S2

S3

S1

1 2 3 4 5 6 7 8

1 2 3 4 5 6 7 8

1 2 3 4

ON

OFF

ON

OFF

ON

OFF(DDC Only)

OUTINLK1:

UEC-3 BASIC CONFIGURATION

SWITCH POSITIONS

Serial No.

Model Options

UEC-3 BASIC

UEC-3-MPC

Potentiometer

PT20S (R-1)

LogitorqueUEC-3-DDC

Type A

Transformer Type/Tapping

Type B

4 6 0 V

4 1 5 V

3 8 0 V

2 2 0 V

5 7 5 V

5 2 5 V

2 2 0 V

1 1 5 V



3.4 DIP Switch Location and Conventions

The UEC-3 and UEC-3-MPC units are configured using DIP switches S1 and

S2 located on the Single Board Computer (SBC) as shown in

Figure 3-2


Bulletin 440-12100 6/96

Figure 3-2 - Single Board Computer DIP Switch

and Component Location

RAM

34 PinBus connectorfor connectionto DiagnosticTools

EPROM(program storage)

Microprocessorwith EEPROM(permanentvariable storage)

Analog toDigital (A/D)Converter Chip(Optional)

Analog Input

Connector

Reset LEDDigital I/O

Isolation

34 Pin Powerand I/OConnector

SwitchingPre-regulator

Linear 5VRegulator

DIP Switch S1(feature selection)

DIP Switch S2(feature selection)



Figure 3-3 shows an example of a DIP switch and the conventions that are

used in describing the configuration of the DIP switches. An individual switch

position is said to be ON when the switch is in the CLOSED state. In the ON

position, the switch is towards the ON indication on the switch housing and

away from the number designation. All tables showing DIP switch configura-

tions indicate a “1” when the switch state is ON.

Conversely, the switch position is said to be OFF when the switch is in the

OPEN state. In the OFF position, the switch is towards the number designa-

tion and away from the ON indication on the switch housing.The tables indicate

a “0” when the switch is OFF or OPEN.

Care should be taken to assure that the each DIP switch is pushed firmly in

either the open or closed direction.

Figure 3-3 - DIP Switch Conventions

CautionAlways use a small non-metallic tool to move the DIP switches.

NEVER use a pencil because graphite filings may cause short

circuits on the printed circuit boards or in the switches.

NoteIf changes to the DIP switches are made while power is present at

the actuator, it is important to turn the power off and on again in order

to initialize the changes.

To change DIP switch settings for a particular application, refer to the UEC-3

Operation Manual Bulletin# 440-12000 Rev. A.


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8

1 2 3 4 5 6 7 8OFF

ON

Dip Swich

SX-7 Position 7



If sufficient information is provided at the time of order, the DIP switches will

be set according to the order. If the specific details are not provided at time of

order, the actuator will be provided with the default settings shown in

Figure 3-4.

‘ESD’ action - ‘CLOSE’ - S1-1,-2 Remote control mode - 4 WIRE - S2-1,-2-3

Local inching - DISABLED - S1-3 Seating method at ‘close’ - POSITION - S2-4Modulating mode - DISABLED - S1-4 Autophase control - ENABLED - S2-5

Slow speed opening - DISABLED - S1-5 Slow speed closing - DISABLED - S2-6

Closing rotation - CLOCKWISE - S1-6

Thermostat bypass - DISABLED - S1-7 NOTE: FOR A STANDARD UEC-3

Interlock / Inhibit - DISABLED - S1-8 ALWAYS SELECT:

EEPROM - DISABLED - S2-7

Software Control - ENABLED - S2-8

Figure 3-4 - Default DIP Switch Settings for UEC-3 and UEC-3-MPC

3.5 EPROM Care and InstallationNormally you will not need to handle the EPROM. However, if you do

need to handle the EPROM, (for example, to install a firmware upgrade),

you should follow these instructions.

3.5.1 EPROM Care and StorageThe UEC-3 family of control modules are equipped with EPROM integrated

circuits (IC) which are fragile and static sensitive. Care should be taken in the

storage and handling of the EPROMs.

Do not ship or store EPROMs near strong electrostatic, electromagnetic, mag-

netic or radioactive fields.

Do not remove labels from EPROMs.

Store EPROMs away from direct sunlight at temperatures from -40°C to

85°C (-40°F to 185°F).

Store EPROMs in static free containers with care to prevent breakage from

shock or damage to pins.


Bulletin 440-12100 6/96

S1ON

OFF 1 2 3 4 5 6 7 8

ONOFFKEY

S2ON

OFF 1 2 3 4 5 6 7 8



3.5.2 EPROM RemovalIt is recommended that an integrated circuit (IC) inserter/extractor tool be used

to remove EPROMs from the socket.

If an IC inserter/extractor is unavailable, use the following procedure:

Carefully insert a small flathead screwdriver into the space between theEPROM and the socket. Slowly and gently pry the EPROM out of the socket

taking care not to bend or break the pins.

3.5.3 EPROM InstallationIt is recommended that an IC inserter/extractor be used to hold the EPROM

for installation.

To insert a replacement EPROM, use the following procedure:

The notch at the top of the EPROM must be lined up with the notch at the top

of the socket.Failure to position properly will result in damage to the EPROM.

Gently place the pins of one side of the EPROM in the socket.Roll the EPROM

over until the pins on the other side are lined up.You may have to use someback pressure to get the pins to line up. When you are sure all pins are lined

up with the socket holes, push down on the top of the EPROM firmly until the

pins are well seated in the socket.

3.6 Supply Voltage

The transformer voltage on the UEC module will be factory set to the supply

voltage specified at the time of order.This setting is recorded, at the factory,

on the label affixed to the side of the UEC housing.

The following procedure should be used to change the transformer voltage:

Tools required to change the transformer voltage:

Medium phillips head screwdriver

Flat blade screwdriver

Long-handled needle nose pliers

No additional parts are required to change the transformer voltage

1. Isolate power from actuator.

2. It is not necessary to remove wires from terminal strip to termination/inter-

connect board.

3. Remove the larger clear cover by pressing down with both thumbs on

indented areas on top edge of cover.

4. Unlatch and release the 34-pin ribbon cable connector on the SBC located

near the heat sink.

5. Remove the four screws securing the SBC and remove the SBC.

6. Remove the insulator sheet.


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10




Bulletin 440-12100 6/96

1

Figure 3-5

Locating Power Supply Board

Figure 3-6

Locating Power Supply Board

Mounting Screw

7. Unlatch and release the 50 pin connector located on the Power Supply

Board between the fuse cartridge and the phase LEDs. Move this ribbon

cable over the edge of the enclosure to permit access to the metal plate.

8. Remove the four screws securing the metal plate. Insert a flat blade screw-

driver under the plate and gently lift and set aside. This plate will be

connected to the assembly via a green ground wire. It is not necessary toremove the ground wire from the plate.

9. Locate the Power Supply Board which is mounted on the wall of the enclo-

sure opposite the Termination/Interconnect board. See Figure 3-5.

10. Remove and retain the single screw from the outside of housing which

secures the power board from the bottom. See Figure 3-6.

11. Using a long phillips head screwdriver, partially unscrew the screw located

on the inside base of the UEC housing which holds the bracket to the

housing. See Figure 3-7. Unscrew only enough to separate the bracket

from the housing. DO NOT COMPLETELY REMOVE THIS SCREW.

12. Slide the power board slowly up and out of the housing being careful to

move wiring aside. Care should be taken to prevent damage to the wiring

insulation by coming into contact with the edges of the bracket. It is onlynecessary that the power board be moved enough to locate and change

the transformer jumpers.

(continued on next page)

Termination/

Interconnect Board

Power Supply Board

Power Supply

Board Mounting Screw



13. Locate the transformer jumpers as shown in Figure 3-8.

14. Using pliers, carefully remove the jumper and reinsert into position for the

desired input voltage:

Std. Optional

LK1 for 460V 575V

LK2 for 415V 525VLK3 for 380V 220V

LK4 for 220V 115

15. If the main power is single phase, set all three LK7 jumpers (located beside

the ribbon cable connector) to the 1 phase setting to disable phase detection.

16. Carefully slide the power board back into the housing.

17. Tighten the bracket screw at the base of the housing.

18. Replace and tighten the screw on the outside of the housing.

19. Replace the metal plate and secure with 4 screws.

20. Reconnect the 50-pin ribbon connector.

21. Replace the insulator sheet on top of the ribbon cable keeping the 34-pin

connector free.

22. Reconnect 34-pin connector into the SBC.23. Replace the SBC and secure with 4 screws.

24. Replace the UEC clear cover.

25. It is recommended that the new voltage with date changed be recorded

and initialed on the label located on the side of the UEC housing.


Bulletin 440-12100 6/96

12

Figure 3-7 -

Locating Power Supply

Bracket Retaining Screw

Figure 3-8 -

Power Supply Board

Power Supply

Bracket

Retaining

Screw

Transformer

Jumpers

LK7 - Phase

Detector

Jumpers



4. UEC-3/UEC-3-MPC Installation

4.1 Site Preparation

Proper site preparation is essential to the successful operation of the UEC-3

controlled actuators.

1. A site map or detailed site plan should be available.This should include

location and tag numbers of all actuators, junction boxes and terminal

strips.

2. Free access to the control compartments of each actuator will be required

for set-up, configuration and troubleshooting.

3. All wires should be properly labeled or identified.

4. Control and power wiring for the actuator should both be installed in proper

conduit but never in the same conduit.Shielding is not enough to prevent

induction of stray voltages onto signal leads from power lines.5. Power distribution grid should be available to identify the impact of power

isolation to a particular actuator or group of actuators.

4.2 Visual Inspection

The UEC module contained in your Limitorque actuator has been tested prior

to shipment. It is recommended that a visual check of the module take place

prior to applying power to the actuator.

• Check for any physical damage to the UEC module

• Verify that all ribbon cables are fully seated and that the clips are in a verti-

cal position.

• Verify that all EPROMs are properly aligned and fully seated.

4.3 Wire Preparation

For connections to the Termination/Interconnect Board, an 18 gage, 380V wire

is recommended. All wires should be stripped 0.25 inch (6 mm) from the end

and tinned with resin core solder for best results.

4.4 Actuator Wiring

It is essential that all wir ing is in accordance with the wiring diagram provided

with your actuators. Copies of the wiring diagram are mailed to purchasers of

Limitorque actuators and one copy is normally placed inside the actuator’s

control compartment before shipment. Becoming familiar with the wiring

diagram will ease setup.

Wiring Verification should be done with the actuator isolated from power.


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1



Note:The transformer voltage on the UEC module will be factory set to suit

the supply voltage specified at the time of order. This setting is

recorded, at the factory, on the label affixed to the side of the UEC

housing.

1. Check to make sure that the transformer voltage on the UEC-3 label is

the same as the incoming supply. If not, refer to Section 2.6 -Supply

Voltage for the procedure to change the voltage.

2 Verify that actuator wiring is in accordance with the wiring diagram shipped

with the actuator.

3. If the external control voltage is above 90VAC or 90VDC, link LK1 must be

removed. Locate LK1 at the bottom of the Termination/Interconnect Board

near the SBC. To remove, grasp the black housing and pull straight up.

4. Verify that DIP switch settings on the SBC are correct to enable the desired

functionality. See Section 2-3 of this manual for DIP switch key and basicsettings.

The unit is now ready for commissioning. See Section 5 for instructions.

4.5 Grounding

The remote control inputs on the Termination/Interconnect Board are opto-iso-

lated to protect the internal logic circuits from high voltage transients and

ground loops. Additional grounding for these inputs is not required.

Please refer to the wiring diagram for your particular Limitorque actuator for

additional grounding requirements.


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5. UEC-3/UEC-3-MPC Commissioning

5.1 Initial Checkout

All UEC-3 and UEC-3-MPC modules and their corresponding actuators are

tested before shipment to ensure proper operation. After assembly, the actu-

ator is cycled through normal operation, thereby assuring that the motor, wiring,

and controller are all functioning properly.

Final setup is not complete until the actuator is installed. Field setup is required.

Please use the instruction and maintenance manual appropriate for your actu-

ator to adjust the limit and torque switches.

Verify that the connectors for the r ibbon cables are properly seated and that

the clips are in closed position.

Verify that all socketed integrated circuits are properly aligned and fully seated.

Make sure that for MPC applications, the Analog to Digital Converter chip is

installed.

5.2 Start-up Procedure

The start-up procedure for the UEC-3 and UEC-3-MPC is given in the form of

a flow chart in Figure 5-1.

Note:The settings of the DIP switches S1 and S2 on the SBC Board should

be recorded before beginning any procedure.


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Figure 5-1 - UEC-3/UEC-3-MPC Start-up Procedure


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16

Do you wantphase correction?

SW2-5 on

Power off,then on

Yes

Set positionlimits

Center Potat 50% valve

position.Selector switch

to ‘Local’

No

Power offSwap incoming power leads

Power on

Yellow LED on?(Phase Rotation OK)

SW2-5 off

Power off,then on

Yes

No

Testpushbuttons

Open PB=> Open dirClose PB=> Close dir

Verify

Change position of SW1-6(Direction to close)

No

Power off,then on

Yes

Change other optionsas required in std.

configuration

Power off,then on

Wait 15 sec

SW93 LED’s on?See Section 6.4Troubleshooting

NoYes

UEC-3-MPCgo tocalibrationprocedure

UEC-3 End ofStart-up



5.2.1 Power LEDsDuring start-up check the LEDs on the power supply board. (See Figure 5-1

of Bulletin 440-12000 Rev. A. for the location of the LEDs.)

The Power Supply Boards on most versions of the UEC-3 and UEC-3 MPC

Modules have three LED indicators - red, yellow, and green.The state of theseindicators for various operating conditions are given below:

On units which have been configured for three phase power, both the red and

yellow LEDs should be illuminated when power is present to the actuator, and

the green indicator should not be illuminated

If the yellow LED is not illuminated, the unit is out of phase and incoming power

leads (L1 & L3) should be switched.

If the red LED is not illuminated, one of the phases is not present and incom-

ing power connections should be checked.

On units which have been configured for three phase power, all of the LEDs

should be illuminated when power is present to the actuator.

The green LED indicates that the phase detector circuit has been bypassed

and that there is no phase protection.

5.2.2 Reset LEDDuring Start-up, check the Reset LED on the Single Board Computer. (See

Figure 5-2 of Bulletin 440-12000 Rev. A. for the location of the RESET LED.)

On all UEC modules the Reset LED should be steadily illuminated when power

is present to the actuator.

If Reset LED blinks every 1.5 sec, check that EPROMs are properly seated

and that no pins are damaged or missing.

If Reset LED blinks every 11-12 seconds, check that module is not in extended

configuration mode.

See Bulletin 440-12000 Rev. A. for other faults which may cause this LED to

blink.


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5.3 UEC-3-MPC Calibration Procedure

The calibration procedure for the UEC-3-MPC is given in the form of a flow

chart in Figure 5-2. This procedure is also discussed in the Operation Manual.

*NoteSpan and Zero reference must always be changed together

Figure 5-2 - UEC-3-MPC Calibration Procedure (Sheet 1 of 4)


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SW2-1,2&3 on

SW2-5,6,7 off

Selector switch

to Local

Press Open buttonWait until actuator

stops at OPEN

Set SW2-5 ON

Press Close buttonWait until actuatorstops at Closed

Set command asneeded (20mA?)

Set command asneeded (4mA?)

Change positionof SW2-4

Change position ofSW2-4

Setting Spanand Zero*

AreMPC parameters

stored?

No

YesSkip to section thatrequires adjustment

Go to Test(Sheet 3)



NoteThe default level for proportional band was factory set at ± 14.0%

NoteDefault level for deadband was factory set at ± 1.0%



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1

Set S1 to the desiredvalue as shown onTable 5-1

Change the positionof SW2-4

Set SW2-1,2,3,6 & 8 ON

Set SW2- 5 & 7 OFF

Go to Test(Sheet 3)

Set ProportionalBand

Set S1 to the desiredvalue as shown onTable 5-1

Change the positionof SW2-4

Set SW2-1,2,3,5,6 &8ON

Set SW2- 7 OFF

Go to Test(Sheet 3)

Set Deadband





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20

Set S1 for desiredaction.*

Change the positionof S2-4

Set S1-3,4,5,6,7,8OFF

Set S2-1,2,3,7 & 8ON

Set S2- 5 & 6OFF

Go to Test

Set Action OnLoss of Signal

*S1-1 S1-2 Act ion

OFF OFF CLOSE

ON OFF STOP

ON ON OPEN



Figure 5-2 - UEC-3-MPC Calibration Procedure

(Sheet 4 of 4)


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2

Set S2-1,2,3,5,7 & 8 on

Change the position of SW2-4

No

Actuatormovement properlyfollows command

signal?

See Section 6.4Troubleshooting

No

Controlsatisfactory(response

time, overshoot,accuracy?)

Yes

Yes

Apply external 4-20mA command

signal

Selector Switch to Remote

S2-1,2,3,5,6,7,8ON

Change position ofS2-4

S2-2 off

Test Responseto Signal

Exit Extended

Configuration

SAVE TO EEPROM

Remove external4-20mA

command signal

Loss of signalaction correct

?

Yes

No

See Section 5.4Troubleshooting

Adjust proportionalband & deadbandSee Sheet 2

End calibrationSet S1 &2 for desired features

Power OFF then ON

Set action onloss of signal



Table 5-1 - Table of Values for Proportional Band and Deadband

% DIP S1 % DIP S112345678 123456 78

1 10000000 26 01011000

2 01000000 27 11011000

3 11000000 28 00111000

4 00100000 29 10111000

5 10100000 30 01111000

6 01100000 31 11111000

7 11100000 32 00000100

8 00010000 33 10000100

9 10010000 34 01000100

10 01010000 35 11000100

11 11010000 36 00100100

12 00110000 37 10100100

13 10110000 38 01100100

14 01110000 39 11100100

15 11110000 40 00010100

16 00001000 41 10010100

17 10001000 42 01010100

18 01001000 43 11010100

19 11001000 44 00110100

20 00101000 45 10110100

21 10101000 46 01110100

22 01101000 47 11110100

23 11101000 48 00001100

24 00011000 49 10001100

25 10011000 50 01001100


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5.4 Troubleshooting

If no Pushbutton Station LEDs are illuminated, see the Troubleshooting Charts.

(See Figures 9-2, 9-3, and 9-4 of the Operation Manual.)

5.4.1 Troubleshooting ToolsLimitorque has developed diagnostic tools to aid in troubleshooting UEC-3

and UEC-3-MPC controlled actuators. The use of either of these tools will

assist in the quick diagnosis of actuator alarms and faults.

5.4.1.1 Universal Diagnostic Tool

The Universal Diagnostic Tool (UDT) is a hand held device that can determine

and diagnose the source of valve actuator alarms and faults on any UEC- 3

or UEC-3-MPC based actuator. It is designed as a first-level diagnostic tool

providing preliminary troubleshooting information and is very easy to use.

Please refer to the UEC-3 and DDC-100 Diagnostic Interface Installation and

Operation Manual - Bulletin 437-10000 for instructions on using the UDT.

5.4.1.2 Modsim Diagnostic Software

A personal computer and Modsim diagnostic software can be used to trou-

bleshoot the UEC-3 controlled actuator. Modsim is designed to provide detailed

diagnostic information in addition to the information provided by the UDT.

Please refer to the UEC-3 and DDC-100 Diagnostic Interface Installation and

Operation Manual - Bulletin 437-10000 for UEC-3 to PC connectivity.

Please refer to the Modsim Modbus Simulation Software Operation Manual -

Bulletin 435-23001 for instructions for using Modsim.


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5.4.2 Component ReplacementLimitorque recommends the field replacement of Control and I/O Power Supply

fuses, Single Board Computer, and Termination /Interconnect Board. If any

other components within the UEC-3 or UEC-3-MPC module require replace-

ment, it is recommended that the complete UEC-3 or UEC-3-MPC module be

replaced. See Section 5.4.3 for instructions on replacing the completeUEC module.

5.4.2.1 Control Fuse Replacement

The following procedure should be used to replace the 120V control power

fuse (FS3) on the Power Supply Board:

Tools required:

Small flathead screwdriver

Parts Required:

Control fuse: P/N: EF2-5X20MM-1A-250V

1. ISOLATE POWER FROM THE ACTUATOR.

2. Remove cover bolts and open control compartment cover.

3. Remove the larger clear cover of the UEC-3 by pressing down with both

thumbs on indented areas on top edge of cover.

4. Locate the fuse cartridge near the 50 pin IDC connector and the heat sink.

5. Insert screwdriver into slot on cap of fuse cartridge and turn 90°in the

direction of the arrow.

6. Lift cap with fuse out of the cartridge.

7. Pull fuse out of cap and replace with Limitorque P/N: EF2-5X20MM-1A-

250V

8. Inspect replacement fuse to confirm that it is the correct size and undam-

aged.

9. Be sure to insert replacement fuse firmly in cap.

10. Align the brackets on the cap and fuse assembly with the notch in the car-

tridge and push straight in to insert.

11. Insert screwdriver into slot on cap of fuse cartridge and turn 90°opposite

direction of ARROW.

12. Replace clear cover.


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5.4.2.2. 24 VDC I/O Power Supply Fuse Replacement

Tools required:

Small flat head screwdriver

Parts required:24VDC I/O Power Fuse P/N: EF2-5X20MM-1A-250V

1. ISOLATE POWER FROM ACTUATOR.


3. To gain access to the Termination/ Interconnect Board, remove the smaller

clear cover on the UEC-3 by inserting a flat head screwdriver in the gap

at the front of the cover and lifting up and towards the base of the housing.

4. Locate the fuse near the pushbutton station IDC connector.

5. Remove the protective shroud from the fuse by inserting the screwdriver

blade under the shroud at each end and pry gently.

6. Remove fuse by inserting the screwdriver blade under one end of the fuseand pry gently until it is free from the fuse holder.

7. Inspect the replacement fuse (Limitorque P/N: EF2-5X20MM-1A-250V)

to confirm that it is the correct size and undamaged.

8. Insert the replacement fuse by lining up the metal ends with the metal

brackets on the fuse holder and pushing the fuse straight down into the

fuse holder.

9. Replace protective shroud over the fuse and holder.To ease replacement,

squeeze the ends of the shroud gently to expand as you are replacing.

10. Replace clear plastic cover.


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5.4.2.3. Single Board Computer (SBC) Replacement

The following procedure should be used to replace the SBC:

Tools required:

Medium phillips head screwdriver

Small non-metallic tool for DIP Switch setting

Parts Required:

Single Board Computer: P/N: 61-825-0996-1





4. Unlatch and release the 34-pin ribbon cable on the SBC located near the

heat sink.

5. Remove the four screws securing the SBC and remove the board.6. It is not necessary to replace the insulator sheet with a new sheet unless

visible damage is present.

7. Inspect replacement SBC for obvious damage and verify that the Analog

to Digital Converter (ADC) chip (if required) is installed.

NoteMake sure that Analog to Digital Converter (ADC) chip is installed

for modulating applications.

8. Connect the 34-pin connector into the replacement SBC.

9. Position replacement SBC on top of the insulator sheet and secure with

four screws.

10. Set the DIP switch on the replacement SBC to match the one being

replaced.

11. Replace the UEC-3 clear cover.


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5.4.2.4.Termination/Interconnect Board Replacement

The following procedure should be used to replace the Termination

/Interconnect Board:

Tools required:

Medium phillips head screwdriverSmall flat head screwdriver

Parts required:

Termination/Interconnect Board: P/N: TM74-743-0050





4. Unlatch and remove the 50 pin ribbon connector located at the end of the

Termination/Interconnect Board adjacent to the SBC near the 34 pin con-nector. Return the release latches to the closed position.

5. Remove smaller clear cover by inserting a flat head screwdriver in the gap

at the bottom of the cover and lifting up and towards the base of the

housing.

6. Disconnect all incoming wires to the Termination/Interconnect Board. Make

sure all wires are labeled for easy reconnection.

7. Position latches for both IDC connectors on the Termination/ Interconnect

Board to the closed position before attempting to remove.

8. Remove and retain the 4 mounting screws on the Termination/Interconnect

Board. Pull the Termination/Interconnect Board away from the SBC to clear

the 50 pin connector to remove.

9. Inspect the replacement Termination/Interconnect Board for obvious

damage.

10. Position latches for both IDC connectors on the replacement Termination/

Interconnect Board to the closed position before attempting to install.

11. Install the replacement board by gently inserting the 50 pin connector into

the slot adjacent to SBC.The 40 pin connector will fit in the slot provided.

Secure this board with 4 mounting screws.

12. Reconnect wires to the terminals on the replacement Termination/

Interconnect Board.

13. Replace small clear cover.

14. Reconnect the 50 pin ribbon cable to the Termination/Interconnect Board.

15. Replace larger clear cover.

16. Reconnect IDC connector (J6).


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5.4.3 Complete UEC-3 or UEC-3-MPC Module ReplacementThe procedure for the replacement of the complete UEC-3 or UEC-3-MPC

module is as follows:

Tools required to replace the complete UEC-3 or UEC-3-MPC Module:

Small flat blade screwdriverMedium flat blade screwdriver

Small non-metallic DIP switch tool

Parts Required:

Replacement UEC-3 or UEC-3-MPC Module - contact your local distributor

or Limitorque Parts Department for correct P/N for your application.



3. Disconnect leads from the UEC module at the terminal strip.

4. Disconnect ribbon cable connections to Pushbutton Station and gearedlimit switch at Termination/Interconnect Board.

5. Disconnect remaining Termination/Interconnect Board wiring to other

devices such as an R/I converter.

6. Remove and save the 4 mounting screws on the base of the UEC module

and remove the assembly.

7. Set the DIP switches on the SBC of the replacement module to match

those of the module removed.

8. Check to make sure that the transformer voltage on the replacement

module is the same as on the module removed. If not, please refer to

Section 2.6 - Supply Voltage for the procedure to change the voltage.

NoteReplacement UEC-3 and UEC-3-MPC modules are shipped with 460V

transformer voltage as standard unless otherwise specified on parts

order.

9. Mount the new UEC-3 module on the mounting plate using 4 screws.

NoteFor replacement in L-120 actuators, it is necessary that the module

be secured first by the mounting screw closest to the input wires,

followed by the screw on the opposite side of the box.These should

hold the module secure while the remaining screws are put in.


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10. Reconnect wiring and ribbon cables to the Termination/Interconnect Board.

11. Connect wires from UEC-3 module to terminal strip according to wiring

diagram supplied with actuator.

12. Reapply power to the actuator.

13. Verify proper operation. See Section 5.2.


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6. Conversion of the UEC-3Basic Controller

An installed UEC-3 control module can be modified in the field to operate asa UEC-3-MPC controller.These changes should be performed by a qualified

technician using genuine Limitorque parts and following the procedures in this

section. All tools and parts required are listed in each procedure.

6.1 Converting UEC-3 to

UEC-3-MPC Position Controller

The UEC-3-MPC is a 4-20 milliAmp controller which will change the position

of the valve in proportion to a current signal received from a set point con-

troller or similar device.

An actuator originally supplied with UEC-3 controls may be changed to UEC-

3-MPC controlled actuator.

The following procedures should be used to convert a UEC-3 actuator to a

UEC-3-MPC actuator:

Tools required:

Small non-metallic DIP switch tool

Small flat blade screwdriver

Medium flat blade screwdriver

Parts required:

Feedback potentiometer: Consult factory for part required

Analog Interface Board: P/N: 61-825-0962-2

A/D Converter Chip: P/N: 61-825-0733-1

Optional UEC-3-MPC parts:

PT20SD Position Transmitter: P/N: TM74-743-0066


2. Remove actuator cover bolts and open control compartment cover.

3. Install potentiometer if not already installed in actuator. See actuator

Instruction and Maintenance manual for installation instructions or contact

your local Limitorque distributor for information.

4. Install Analog Interface Board. Analog board installation differs with type

and size of actuator. Consult factory or nearest service center for instal-

lation instructions.


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3



5. Remove the large clear cover on the UEC-3 module and connect ribbon

cable, J3A, from the Analog Interface Board to J3 connector on the Single

Board Computer (SBC).When the cover is replaced, the ribbon cable will

fit through the cut-out in the cover.

6. Before replacing the cover, install the Analog to Digital Converter chip into

U18 on the Single Board Computer being careful to match notches andavoid bending pins.The location of the Analog to Digital Converter (U18)

is shown in Figure 5-2 of the Operation Manual.

7. Calibrate the UEC-3-MPC (See UEC-3 Operation Manual - Bulletin 440-

12000 Rev. A., and Section 5.3 of this manual for calibration procedure).

6.1.1 Installation of the PT20SD (Optional)The procedure and parts required for the installation of PT20SD differs accord-

ing to the type and size of Limitorque actuator. Please consult the nearest

Limitorque Blue Ribbon Service facility or Limitorque’s Service Department

for assistance.


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7. Parts

X indicates that parts are standard.

O indicates that parts are optional.

Item Part Number UEC MPC

Single Board Computer 61-825-0996-4 X X

Termination/Interconnect Board 61-825-1060-3 X X

3 Phase Power Supply Board 61-825-1235-4 X X

Single Phase & Special Power Supply Boards 61-825-1234-4 O O

Primary Fuses (FS1 & FS2) EF4-TDC11-250MA X X

Control Fuse (FS3) EF2-5X20MM-1A-250V X X

24VDC I/O Power Fuse (FS4) EF2-5X20MM-1A-250V X X

PT 20SD TM74-743-0066 O O

SBC Analog Board 61-825-0962-2 X

SW93 Pushbutton Station TM74-790-0033 X X

Customer Service Kit TM0700504 O O

Universal Diagnostic Tool 61-825-0950-3 O O

UDT Serial Interface Adapter 61-825-0951-3 O O

ADC Chip 61-825-0733-1 X

NotePart Numbers are subject to change as product improvements are

introduced. Consult Limitorque for current part numbers.


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8. Customer ServiceFor parts or parts information, call your local Limitorque distributor or the Parts

Department in Lynchburg, VA, at 804-522-9833. For fastest response, please

have the order number and serial number from the actuator available when

contacting Limitorque for parts or parts information. This information can befound on a Limitorque label affixed to the main housing of the actuator.

For service information, call your local Limitorque distributor, Blue Ribbon

Service Center or the Service Department in Lynchburg, VA, at 804-845-9366.

For fastest service, please have the order number and serial number from the

actuator available when contacting Limitorque with service questions. This

information can be found on a Limitorque label affixed to the main housing of

the actuator.


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3



Limitorque ®

Bulletin 440-12100 6/96

For further Limitorque service assistance call:

Limitorque Corporation

7615 Boeing Drive

Greensboro, NC 27409-8347

Phone (910) 668-0871

Fax (910) 605-5310


8901 Jameel Road Suite 180

Houston, TX 77040

Phone (713) 690-1960

Fax (713) 690-1277

or contact the Limitorque offices listed below


5114 Woodall RoadP.O. Box 11318Lynchburg, VA

24506-1318Phone (804) 528-4400

Fax (804) 845-9736

Limitorque International

Trinity HouseKennet SideNewburyBerkshire, RG15 5EH EnglandPhone 44-1-635-46999Fax 44-1-635-36034

Limitorque/Nippon Gear Co. Ltd.Tennoz Central Tower 2-2-4,Higashi-Shinagawa,

Limitorque of India, Ltd.

E-45/2 Okhla Industrial Area,Phase-IINew Delhi 110 020, IndiaPhone 91-129-277135Fax 91-11-683-9329

Limitorque Australia Ltd.Division of Control Engineering(Aust.) Pty., Ltd.17 Scoresby Road

Limitorque Asia Pte Ltd.

75 Bukit Timah Rd.#05-01/02 Boon Siew BuildingSingapore 229833Phone 65-332-9100Fax 65-332-9112

Documents

Uec 3 & Uec3 Mpc Manual440-12100