Honeywell UMC800 User Manual

UMC800 Controller

Installation and User Guide

Doc. No.: 51-52-25-61

Release: F

Last Revision Date: 4/01

Sensing and Control

Notices and Trademarks

Copyright 2001 by Honeywell

Release F April, 2001

Warranty/Remedy

Honeywell warrants goods of its manufacture as being free of defective materials and faulty workmanship. Contact
your local sales office for warranty information. If warranted goods are returned to Honeywell during the period of
coverage, Honeywell will repair or replace without charge those items it finds defective. The foregoing is Buyer’s sole
remedy and is in lieu of all other warranties, expressed or implied, including those of merchantability and
fitness for a particular purpose. Specifications may change without notice. The information we supply is believed
to be accurate and reliable as of this printing. However, we assume no responsibility for its use.

While we provide application assistance personally, through our literature and the Honeywell web site, it is up to the
customer to determine the suitability of the product in the application.

Sensing and Control

Honeywell

11 West Spring Street

Freeport, Illinois 61032

Honeywell is a U.S. registered trademark of Honeywell

Other brand or product names are trademarks of their respective owners.

ii UMC800 Controller Installation and User Guide Release F

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About This Document

Abstract

This document provides descriptions and procedures for the installation, operation and maintenance of the UMC800
Controller hardware.

References

The following list identifies all documents that may be sources of reference for material discussed in this
publication.

Document Title ID #

UMC800 Technical Overview Specification 51-52-03-24
UMC800 Operator Interface User Guide 51-52-25-62
UMC800 Control Builder User Guide 51-52-25-63
UMC800 Function Block Reference Guide 51-52-25-64
UMC800 RS232 Communications Reference Manual 51-52-25-76

UMC800 User Utility User’s Guide 51-52-25-77
Modbus® RTU Serial Communications User Manual 51-52-25-87
How to Apply Digital Instrumentation in Severe Electrical Noise Environments 51-52-05-01

Contacts

World Wide Web

The following lists Honeywell’s Wor ld Wide Web sites that will be of interest to our customers.

Honeywell Organization WWW Address (URL)

Corporate
Sensing and Control
International

Telephone

Contact us by telephone at the numbers listed below.

Organization Phone Number

United States and Canada Honeywell 1-800-423-9883 Tech. Support

Asia Pacific

Europe Honeywell PACE, Brussels, Belgium [32-2] 728-2111
Latin America Honeywell, Sunrise, Florida U.S.A. [phone]

Honeywell Asia Pacific
Hong Kong

http://www.honeywell.com
http://www.honeywell.com/sensing
http://www.honeywell.com/Business/global.asp

1-888-423-9883 Q&A Faxback

(TACFAQS)

1-800-525-7439 Service
(852) 2829-8298

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Symbol Definitions

The following table lists those symbols that may be used in this do cument to denote certain conditions.

Symbol Definition

This DANGER symbol indicates an imminently hazardous situation, which,
if not avoided, will result in death or serious injury.

This WARNING symbol indicates a potentially hazardous situation, which, if
not avoided, could result in death or serious injury.

This CAUTION symbol may be present on Control Product instrumentation
and literature. If present on a product, the user must consult the
appropriate part of the accompanying product literature for more
information.

This CAUTION symbol indicates a potentially hazardous situation, which, if
not avoided, may result in property damage.

WARNING

PERSONAL INJURY: Risk of electrical shock. This symbol warns the user of a

potential shock hazard where HAZARDOUS LIVE voltages greater than 30 Vrms,

42.4 Vpeak, or 60 Vdc may be accessible. Failure to comply with these

instructions could result in death or serious injury.

ATTENTION, Electrostatic Discharge (ESD) hazards. Observe precautions for
handling electrostatic sensitive devices

Protective Earth (PE) terminal. Provided for connection of the protective earth
(green or green/yellow) supply system conductor.

Functional earth terminal. Used for non-safety purposes such as noise immunity
improvement. NOTE: This connection shall be bonded to protective earth at the
source of supply in accordance with national local electrical code requirements.

Earth Ground. Functional earth connection. NOTE: This connection shall be bonded
to Protective earth at the source of supply in accordance with national and local
electrical code requirements.

Chassis Ground. Identifies a connection to the chassis or frame of the equipment
shall be bonded to Protective Earth at the source of supply in accordance with
national and local electrical code requir eme nts.

Earth Ground. Functional earth connection. NOTE: This connection shall be bonded
to Protective earth at the source of supply in accordance with national and local
electrical code requirements.

Chassis Ground. Identifies a connection to the chassis or frame of the equipment
shall be bonded to Protective Earth at the source of supply in accordance with
national and local electrical code requir eme nts.

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Contents

Introduction.............................................................................................1

Purpose........................................................................................................................1

UMC800 Controller ......................................................................................................2

CE Conformity (Europe)...............................................................................................2

UMC800 Overview.................................................................................. 3

UMC800 Description....................................................................................................3

Feature Summary.........................................................................................................4

Equipment Identification..........................................................................5

Controller Components ................................................................................................5

Operator Interface........................................................................................................7

Control Builder..............................................................................................................8

Serial Communication Ports.......................................................................................10

Pre-Installation Considerations............................................................. 11

Introduction.................................................................................................................11

Mounting and Wiring.............................................................................15

Site Preparation..........................................................................................................15

Mounting the Controller..............................................................................................16

Plug-in Module Locations...........................................................................................18

Signal Wiring..............................................................................................................23

Wiring Communication Links......................................................................................36

Remote Access..........................................................................................................44

Power Supply Wiring..................................................................................................51

Operation..............................................................................................52

Power Up / Power Down............................................................................................52

Operational Modes and Controls ...............................................................................53

File Downloading........................................................................................................56

Code Download..........................................................................................................57

Warm Start / Cold Start ..............................................................................................58

Status Indicators.........................................................................................................59

RS 485 Port Configuration (Communication Board Option) ......................................61

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Maintenance .........................................................................................63

Overview ....................................................................................................................63

Routine Maintenance .................................................................................................64

Controller Calibration .................................................................................................65

Replacement Procedures...........................................................................................70

Diagnostics and Troubleshooting..........................................................79

Overview ....................................................................................................................79

Controller Diagnostics ................................................................................................79

Fault Detection and Troubleclearing..........................................................................81

Parts List...............................................................................................91

UMC800 Controller ....................................................................................................91

Specifications........................................................................................93

Introduction.................................................................................................................93

Controller Design........................................................................................................93

I/O Module Configuration...........................................................................................93

Design........................................................................................................................97

Environmental and Operating Conditions ..................................................................99

PV Inputs..................................................................................................................100

Multilanguage Safety Sheets

Service Centers

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Tables

Table 1 Controller plug-in I/O module types................................................................................................................6

Table 2 Communication port descriptions..................................................................................................................10

Table 3 Operating limits.............................................................................................................................................11

Table 4 Permissible wiring bundles............................................................................................................................ 13

Table 5 Power supply input requirements...................................................................................................................16

Table 6 I/O module identification...............................................................................................................................19

Table 7 I/O module installation limitations................................................................................................................20

Table 8 I/O module identification record....................................................................................................................22

Table 9 Universal analog input module specifications...............................................................................................25

Table 10 Summary of communication link connections to controller........................................................................37

Table 11 Configuration connector pinouts..................................................................................................................37

Table 12 Null modem cable construction...................................................................................................................38

Table 13 Operator interface connector pinouts...........................................................................................................40

Table 14 Power supply wiring....................................................................................................................................51

Table 15 Controller mode switch summary................................................................................................................55

Table 16 Controller downloading summary...............................................................................................................56

Table 17 Scan rates per inputs configured ..................................................................................... .............................58

Table 18 Controller status LEDs.................................................................................................................................59

Table 19 Controller status LEDs.................................................................................................................................80

Table 20 Details of the diagnostic summary display............................................................................ ......................81

Table 21 Details of the I/O module diagnostics display.............................................................................................87

Table 22 Controller modem troubleshooting..............................................................................................................89

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Figures

Figure 1 UMC800 components.....................................................................................................................................3

Figure 2 UMC800 controller hardware.........................................................................................................................5

Figure 3 551 operator interface.....................................................................................................................................7

Figure 4 552 operator interface.....................................................................................................................................7

Figure 5 1041 operator interface...................................................................................................................................7

Figure 6 Typical Control Builder graphic display ........................................................................................................8

Figure 7 UMC800 controller enclosure......................................................................................................................15

Figure 8 UMC800 controller enclosure dimensions...................................................................................................17

Figure 9 UMC800 controller plug-in slots..................................................................................................................18

Figure 10 I/O module PWA and terminal...................................................................................................................19

Figure 11 I/O module terminal block (all except 16 point DI) ...................................................................................23

Figure 12 Field wiring shield termination...................................................................................................................24

Figure 13 AI module terminal block connections.......................................................................................................25

Figure 14 Recommended wiring for one pH sensor input..........................................................................................26

Figure 15 AO module terminal block connections.....................................................................................................27

Figure 16 DI module terminal block connections.......................................................................................................29

Figure 17 DO module terminal block connections.....................................................................................................30

Figure 18 DO module relay contact setting................................................................................................................31

Figure 19 PI/FI module terminal block connections....................................................................................................32

Figure 20 PI/FI Module Input Filter Cutoff Frequency setting...................................................................................33

Figure 21 Pulse / Frequency Input Connections..........................................................................................................33

Figure 22 Pulse / Frequency card digital output connections ......................................................................................35

Figure 23 Communication port connectors.................................................................................................................36

Figure 24 Ferrite clamp installation............................................................................................................................39

Figure 25 Terminal connections.................................................................................................................................41

Figure 26 COMM A and B port wiring (2-wire and 4-wire)......................................................................................42

Figure 27 RS 485 port wiring (2 wire)........................................................................................................................43

Figure 28 Power supply terminal connections............................................................................................................51

Figure 29 Controller mode switch location.................................................................................................................54

Figure 30 Controller status LEDs...............................................................................................................................60

Figure 31 COMM A and B ports on CPU module......................................................................................................61

Figure 32 Controller components that contain calibration values...............................................................................66

Figure 33 AI module terminal block...........................................................................................................................68

Figure 34 AO module jumper ST1.............................................................................................................................69

Figure 35 Controller components and location...........................................................................................................70

Figure 36 Power supply fuse and CPU battery location.............................................................................................72

Figure 37 I/O module terminal blocks (not shown: 16 point DI)................................................................................75

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Purpose

This Installation and User guide assists in the installation, start up, operation, maintenance and
troubleshooting of the UMC800 Controller.

The information in this guide is organized as follows:

Introduction

Purpose

Introduction

Topic Description Page

UMC800 Overview

Equipment Identification A high-level physical and functional description of the

Pre-installation
Considerations

Mounting and Wiring Information and procedures to successfully install the

Installation Checkout and
Power Up

Operation Power up and power down routines, operational modes and

Maintenance Procedures are given covering routine maint enan ce and the

Diagnostics and
Troubleshooting

Provides a concise description of the UMC800 control
system, its applications, architecture and its features

UMC800 components
Lists a number of things to consider when planning the

controller installation. Environmental factors as well as
methods to minimize interference are dis cu sse d.

UMC800 controller and its components. Interconnecting
wiring to other UMC800 components is also covered.

Provides a checklist to complete before power up. Covers
power up procedure.

controls, software download routines, warm and cold start
routines, Status LEDs, and scan rates are covered in this
section.

replacement of controller componen ts. Infor mat ion on I/O
module calibration is presented.

Provides description of controller status and error conditions.
Provides corrective actions necessary to clear fault
conditions.

3

5

11

15

44

52

63

79

Parts List A list of replacement parts for the controller. 91
Specifications

Supplemental Installation
Information

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Summary of electrical, physical, environmental and
performance specification s.

Provides helpful information for installing digital equipment in
severe electrical noise environments.

Refer to document 51-52-05-01 How to Apply Digital
Instrumentation in Severe Electrical Noise Environments.

93

––

Introduction
UMC800 Controller

UMC800 Controller

The UMC800 is industrial process control equipment that must be mounted. The wiring terminals must be
enclosed within a panel.

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.
Deviation from the installation conditions specified in this manual, and the following special conditions,

may invalidate this product’s conformity with the Low Voltage and EMC Directives.

ATTENTION

The emission limits of EN 50081-2 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.

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UMC800 Description

The Universal Multiloop Controller (UMC800) is a modular controller designed to address the analog and
digital control requirements of small unit processes. With up to 16 analog control loops, four setpoint
programmers, and an extensive assortment of analog and digital control algorithms, the UMC800 is an
ideal control solution for furnaces, environmental chambers, ovens, reactors, cookers, freeze dryers,
extruders, and other processes with similar control requirements.

Accommodating up to 64 universal analog inputs, 16 analog outputs, and 96 digital inputs/outputs, the
UMC800 provides the appropriate balance of input and output hardware for these smaller unit processes.

The UMC800 uses separate hardware for control functions and operator interface functions to provide
greater installation flexibility. See Figure 1. The controller incorporates card slots capable of supporting up
to 16 input and output modules that can be mixed to satisfy the hardware requirements of a specific
application. The operator interface uses a color graphic LCD display to provide a variety of display
presentations for viewing control loops, setpoint programs, and other analog and digital status.

UMC800 Overview

UMC800 Description

UMC800 Overview

PC or Laptop with
Control Buil der
Conf igura tion Sof twa re,
On -Li n e H el p an d
User Utility So ftware

UMC800
Co ntroller

OFFLINE

RUN

PROG RAM

CONFIGURATI ON

POWER

LoBA T

FORC E

RUN

Replac e batte ry with T adiran T L510 1/S

See users gui de for ins truct ions.

only. Use of another battery m ay

present a ris k of fir e or expl osio n.

_

DISP LAY

100 - 230 V ~

BAT

50 / 60 Hz

100 VA MAX.

F 3,15 A T

L1

L2 /
N

COMM B COMM A

RS 485 Serial
Communications with
Modbus RTU Protocol
(Option al)

To Field
Devices

Operator Int erface

Figure 1 UMC800 components

A separate “Control Builder” configuration software program is used for system configuration that
operates on a Windows 95- or NT-based PC. The software program uses graphic symbols and line drawing
connections to create custom control strategies. Menus are provided in the software to allow selection of
screens for the operator interface and to customize screen access methods and operator keys. Completed
configurations are loaded into the control system using a dedicated communications port in the controller,
or optionally, via floppy disk. A separate User Utility software program (also running on a PC) is used to
create, edit, save, open and download individual recipe, profile and data storage files. Calibration of the
analog input and output modules can be performed through this utility program. A modem connection

Release F UMC800 Controller Installation and User Guide 3
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UMC800 Overview
Feature Summary

through the Configuration port allows remote access to the controller via the Control Builder and User
Utility programs. This will enable trouble shooting, configuration c hanges and firmware upgrade.

The optional communications board adds two bi-directional, multi-drop RS 485 serial communication
interfaces to the controller CPU module. The COMM A port uses Modbus RTU protocol and is a
master/slave link allowing up to 31 controllers to be connected to a single host computer. The computer
initiates all communication. COMM B port allows the controller to operate as a master device to up to 16
slave Modbus compatible devices. Data transferred through this port is integrated into the user’s control
strategy through read and write function blocks. Applications might include writing controller data (set
points, process variables, etc.) to a strip chart recorder to produce a hard copy of process performance, or to
read data from other controllers.

Feature Summary

• Up to 16 control loops, including:

− Proportional Integral Derivative (PID),

− ON/OFF,

− Three Position Step Control (TP SC) , and

− Carbon Potential.

• Auto-tuning for each control loop

• Up to 64 Universal Analog Inputs

• Up to 16 Analog Outputs

• Up to 96 Digital Inputs/Outputs

• Up to 50 Recipes with up to 50 variables each

• Up to 4 Setpoint Programmers, 3500 total segments

• Setpoint Profile and Recipe storage, up to 70 programs

• Setpoint Scheduler, 10 stored schedules

• Function Block Graphic Configuration with up to 250 blocks

• Large assortment of algorithms for combination of analog and logic functions

• Extensive Alarm and Event monitoring

• Operator interface with a selection of graphic displays

• Carbon Potential, Dewpoint and Relative Humidity Co ntro l

• Optional 3-1/2” floppy disk drive for data archiving, setpoint program and recipe storage

• Universal Power (100 to 240 Vac or Vdc) or 24 VA RH)

• UL, CE, and CSA approved, Y2K compliant C/DC (optional)

• Industrial Operating Range (0 °C to 55 °C, 10 % to 90 %

• UL, CE, and CSA Approved, Y2K compliant

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Equipment Identification

Controller Components

Enclosure

The UMC800 controller illustrated in Figure 2 consists of a single metal enclosure that houses the
following controller components:

• Power supply module that plugs into the controller common backplane.

• CPU module with two serial communications ports. An optional communications board provides two

RS485 serial communication ports (slave and master) that support Modbus® RTU protocol.

• Backplane assembly capable of supporting up to 16 input or output modules.

• Various types of I/O processing modules that plug into the common backplane.

• Removable terminal blocks that connect the I/O modules with the field wiring.

Equipment Identification

Controller Components

• Battery back-up power for RAM and real time clock in the event of power interruption.

12
11
10

9
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6
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4

3
2
1

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10

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4

3
2
1

OFFLINE

RUN

PROGRAM

POWER
LoBAT
FORCE
RUN

Replace battery with Tadiran TL5101/S

only. Use of another battery may

present a risk of fire or explosion.

See user’s guide for instructions.

BAT

CONFIGURATION

_

100 - 240 V ~

DISPLAY

50 / 60 Hz

100 VA MAX.

COMM B COMM A

F 3,15 A T

250V

L1
L2 / N

Figure 2 UMC800 controller hardware

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Equipment Identification
Controller Components

I/O modules

Eleven different module types can be installed in the controller to support both analog and digital inputs
and outputs of various types and signal levels. The signal type and I/O capacity for each module type is
indicated in Table 1.

Table 1 Controller plug-in I/O module types

Module Type Signal Types Maximum

I/O

Universal Analog Inputs (AI) mV, V, mA, T/C, RTD, Ohms 64 4 16
Analog Outputs (AO) 0 mA to 20 mA 16 4 4
Digital Inputs (DI) - 4 types:
AC 100/240 Vac 96 6 16
DC 24 Vdc 96 6 16
Logic Dry contacts

(5 mA - 5 Vdc)
16 point Dry contacts 48 16 3
Digital Outputs (DO) - 4 types:
AC 100/240 Vac 96 6 16
AC

High current outputs

DC 24 Vdc 96 6 16
Relay SPST normally open (NO) or

Pulse Input/Frequency Input 24 Vdc 64 4 16

100/240 Vac

With:

2 outputs rated @ 2 A

4 outputs rated @ 0.5 A

normally closed (NC) contact.

(User configurable)

96 6 16

12 2 12

60 6 10

I/O per

card

Maximum no.

of cards

pH Power Module ± 15 Vdc 8 4 2

NOTE: Total combined digital I/O is 96 points.

Control architecture

The UMC800 uses a function block configuration architecture to develop control strategies for both analog
and digital operations. A function block may represent a physical input or output, a group of physical inputs
or outputs, an internal calculation, or an internal function such as a PID algorithm. More than 70 standard
UMC800 function block algorithm types are available for configuring analog and logic functions.
Typically, a function block algorithm type may be used any number of times up to the limit of 250 blocks.
Some of these with specific limitations are:

• Control loops (i.e., PID, ON/OFF, TPSC, and Carbon potential)—eight or sixteen maximum

• Setpoint programmer and associated support blocks—four maximu m

• Setpoint Scheduler and associated support blocks—one maximum

• Time proportioning output blocks—sixteen maximum

• Pushbutton blocks—four maximu m

• 4 Selector Switch blocks—four maximum

• Modbus Slave blocks—sixteen maximum

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Operator Interface

The UMC800 operator interface (Figure 3, Figure 4, and Figure 5) provides a graphic LCD display and a
monoplaner keyboard to allow operator access to all controller functions. The operator interface becomes
operational once a valid database is configured in the controller. Modification and customization of the
operator interface is performed using Control Builder software. With the software, data points can be
identified (tagged) using eight character names. Once named, these data points may be accessed by the
operator interface using a standard set of display formats and a predefined menu hierarchy. Customized
display access and the assignment of selected displays to keyboard buttons may be developed using Control
Builder software. Selected displays such as bargraphs, trends, and overview displays will require the user to
specify the individual data points to be represented on the display.

Equipment Identification

Operator Interface

F1

F2

F3

ESC

F4

1 2 3 4 5

Figure 3 551 operator interface

?

ALARM

Honeywell

F1

F2

F3

F4

KB

1 2 3 4 5

ESC

?

ALARM

Figure 4 552 operator interface

7 8 9

F1

4 5 6

1 2 3

F2

0 . -

F3

F4

?

ESC

1 2 3 4 5 6 7 8

Figure 5 1041 operator interface

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Equipment Identification
Control Builder

Control Builder

All controller and operator interface configuration is performed using Control Builder software on a
separate PC operating with Windows

TM

95 or WindowsTM NT 4.0. All configuration is performed off-line
(computer disconnected from the controller and operator interface). The configuration is downloaded in a
separate operation as a complete file through a dedicated RS-232 communication port on the controller.
Once a configuration is installed into the controller and operator interface, the Control Builder software
may be used to monitor areas of the configuration to verify proper op eration. Co ntro ller configuration
development is performed using "Drag and Drop” techniques for positioning graphic icons on a CRT
display from a list of available functions. See Figure 6. Signal flow connectio ns from icon to icon complete
the controller configuration. The Control Builder software will create a graphic dia gram 1 page high by 20
pages wide. The completed diagram may be printed on 20 pages of 8.5" x 11.5" paper. Each configuration
is saved as a single PC file. Multiple files may be saved o n the PC. The Control Builder can concurrently
open multiple configuration files.

Figure 6 Typical Control Builder graphic display

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Completed configurations may also be saved on 3.5" floppy disk and loaded into the controller and
operator interface through an optional 3.5" floppy disk drive, eliminating the need for a direct connection of
a PC to the controller.

Each analog signal flow line of the configuration may be labeled with an 8-character name, 4-character
engineering unit definition, and may have a decimal point location specified. Digital signal lines may be
identified with an 8-character name and 6-character ON and OFF label.

Signal tag descriptions are used by the operator interface to present on-line status.
Control Builder software may also be used to reconstruct a n existing controller configuration by uploading

the configuration from the controller for maintenance or diagnostic purposes.
Operator Interface configuration is performed by identifying values to show on predefined display

templates and defining the display access buttons.

Control Builder on-line help

Equipment Identification

Control Builder

The on-line help system provides a convenient and quick way to look up any task you are performing in the
Control Builder program. This Windows
any time you request help, a help topic appears that pertains to where you are in the program. For example,
if you are focused on a particular program window, you will get a help topic that describes that window. If
you are in a particular dialog box or entry field, you will get a help topic that describes that dialog box or
entry field.

Within a help window there may be hotspots which are shown as highlighted text. If you cl ick on the
highlighted text, a pop-up box with a definition or a separate window of information that corresponds to the
designated hotspot topic will appear.

The help menu, which is accessible from any main menu, can be used to display an index and the contents
of all help topics in the program.

A right-click on a Function Block provides topic help for that block.

User utility

A separate user utility program is available, which is a windows-based program, and is designed for end­user administration tasks of the UMC800. This utility allows you to create, edit, and download recipes,
setpoint profiles, setpoint schedules and data storage files. Controller files can be downloaded and uploaded
at the PC. Using the communications menu and dialog boxes, communications parameters can be setup to
match your PC communications settings. A loopback test can be initiated to verify communications
between your PC and the controller, and an error summary provides data for troubleshooting
communications problems. The maintenance menu provides access to controller diagnostic data and allows
users to initiate calibration of selected I/O modules.



help system offers context-sensiti ve he lp which means that at

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Equipment Identification
Serial Communication Ports

Serial Communication Ports

The controller contains dedicated serial ports for external communications. These are described in Table 2.

Table 2 Communication port descriptions

Communication

Port

(on CPU Module)

Configuration

Display

COMM A

(with optional

communication

board)

COMM B

(with optional

communication

board)

Description

Configuration Port - This RS232 port is a dedicated connection for
communications with a PC running the Control Builder configuration program .
The communications link layer protocol is proprietary. Communication is
through a null modem cable or through a modem.

This RS 422 port is a dedicated connection for communications with the
operator interface. Separate power leads included in the cable also supply
power to the operator interface. The communications link layer is proprietary
and not intended for external use.

RS 485 Serial communication port using Modbus RTU protocol. This port allows
the controller to operate as a slave device on a multi-drop bus with up to 31
other UMC800 controllers and Modbus compatible devices. A PC host can be
connected to the bus and used for controller configuration and monitoring tasks.

RS 485 Serial communication port using Modbus RTU protocol. This port allows
the controller to operate as a master device to up to 16 slave Modbus
compatible devices. Data transferred through this port is integrated into the
user’s control strategy through read and write function blocks.

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Introduction

Installation of the controller consists of mounting and wiring the controller according to the guidelines
given in this section. The controller is industrial control equipment that must be panel mounted within an
enclosure. The wiring terminals must be enclosed within the enclosure.

Read the pre-installation information, check the model number interp r etation [Controller model number
(page 21)], and become familiar with your model selections, then proceed with installation.

While the UMC800 has been designed for use in most industrial environments, there are certain
requirements that should be considered regarding installation and wiring to ensure optimum performance.
Many of the problems associated with electronic control equipment can be traced to the primary ac power
system. Disturbance, such as electrical noise, power interruptions, and lightning, must be factored into the
planning of the primary power system so the control equip ment will perform satisfactorily and
continuously.

In addition to the precaution of the separation of signal and power wiring in separate conduits, this section
suggests some other measures that can be taken to minimize the effects of electromagnetic interference
(EMI) and radio frequency interference (RFI), voltage surges and static electricity.

Pre-Installation Considerations

Introduction

Pre-Installation Considerations

Operating limits

We recommend that you review and adhere to the operating limits listed in Table 3 when you install the
controller.

Ambient Temperature
Relative Humidity 10 % to 90 % RH at 40 °C (104 °F)
Vibration

Mechanical Shock

Power

Power Consumption 100 VA Maximum

Table 3 Operating limits

Condition Specifications

32 °F to 131 °F (0 °C to 55 °C)

Frequency
Acceleration

Acceleration
Duration

Voltage
Frequency (Hz)

14 Hz to 250 Hz
1 g

1 g
30 ms

100 V to 240 V (24 V optional)
50/60 Hz or dc

Release F UMC800 Controller Installation and User Guide 11
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Pre-Installation Considerations
Introduction

Electrical considerations

The controller is considered “open equipment” per EN 61010-1, 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.

Controller grounding

PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is installed shall be
in accordance with National Electrical Code (ANSI/NFPA 70) and local electrical codes.

Taking electrical noise precautions

Electrical noise is composed of unabated electrical signals that produce undesirable effects in
measurements and control circuits.

Digital equipment is especially sensitive to the effects of electrical noise. You should use the following
methods to reduce these effects:

• Supplementary bonding of the controller enclosure to a local ground, using a No. 12 (4 mm

conductor, is recommended. This may help minimize electrical noise and transients that may adversely
affect the system.

2

) copper

• Separate External Wiring - separate connecting wires into bundles (see Table 4) and route the individual

bundles through separate conduits or metal trays.

• Use shielded twisted pair cables for all Analog I/O, Process Variable, RTD, Thermocouple, dc millivolt,

low level signal, 4-20 mA, Digital I/O, and computer interface circuits.

• Use suppression devices for additional noise protection. You may want to add suppression devices at the

external source. Appropriate suppression devices are commercially available.

• Refer to document 51-52-05-01 How to Apply Digital Instrumentation in Severe Electrical Noise

Environments for additional installation guidance.

12 UMC800 Controller Installati on and User Guide Release F

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Permissible wire bundling

Table 4 shows which wire functions should be bundled together.

Bundle No. Wire Functions

Pre-Installation Considerations

Introduction

Table 4 Permissible wiring bundles

1

2

3

• Line power wiring

• Earth ground wiring

• Control relay output wiring

• Line voltage alarm wiring

Analog signal wire, such as:

• Input signal wire (thermocouple, 4 mA to 20 mA, etc.)

• 4-20 mA output signal wiring

• Slidewire feedback circuit wiring

• Digital input signals

• Communications

• Low voltage alarm relay output wiring

• Low voltage wiring to solid state type control circuits

Release F UMC800 Controller Installation and User Guide 13
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Pre-Installation Considerations
Introduction

14 UMC800 Controller Installati on and User Guide Release F

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Site Preparation

The UMC800 must be mounted within an enclosure. Hardware is provided to surface mount the controller
to a panel or other suitable surface. Be sure that there is sufficient clearance for mounting the controller
enclosure and the external wiring.

UMC enclosure and components

The controller enclosure houses all circuit assemblies of the UMC controller. See Figure 7. The power
supply and CPU are modules that plug into slots on the right hand side of the enclosure. Both modules have
metal covers on the front where indicators, switches and connectors are located. All external connections to
the power supply and CPU are made on the front panels of these modules.

A front cover can be removed by two screws to access the I/O modules. There are two rows of card guides
to accommodate up to 16 plug-in I/O modules. External signal wiring to field devices are made with
removable terminal blocks that attach to the front of each I/O module. Optional terminal strips can be used
to provide shield termination of field wiring.

Mounting and Wiring

Site Preparation

Mounting and Wiring

Power supply, CPU and I/O modules are connected through a common backplane within the enclosure. All
external wiring for power supply and I/O modules are brought out through rubber grommets located at the
top and bottom of the enclosure. The CPU features two connections for external communications. One
provides a cable connection to a PC for configuration and database file management; the other connection
accommodates a cable to the operator interface. An optional communication board provides two RS 485
serial communications ports (slave and master) using Modbus RTU protocol.

External Wiring
Access Holes

Front
Cover

CPU Module

Power Supply

Figure 7 UMC800 controller enclosure

Release F UMC800 Controller Installation and User Guide 15
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Mounting and Wiring
Mounting the Controller

Power requirements

The standard supply uses 100/240 Vac or Vdc input ranges for its source. The input requirements are listed
in Table 5. Instructions for wiring the power supply are found in Table 5.

100-240 Vac or dc (+10 % or –15 %) 50/60 Hz or dc 100 VA maximum
24 Vac or dc (optional)

24 Vac (+25 % or –15 %) or
24 Vdc (+50 % or –8% )

Assembling parts

Assemble all parts of the UMC800 along with tools required to mount the UMC800 hardware. You should
have these tools on hand:

• Tool box that includes a center punch and a standard complement of flat blade and Phillips head

screwdrivers as well as box-end and open-end wrenches.

Table 5 Power supply input requirements

Voltage Input Frequency Power Consumption

50/60 Hz or dc 100 VA maximum

• A drill tap and drill with number 9 drill bit for drilling clearance holes as ap plicable.

• Tools for measuring and marking location of clearance holes and cutout on panel as well as cutting a

hole in the panel.

Mounting the Controller

Mounting controller enclosure on a panel

The controller enclosure is made to be surface mounted within an enclosure. The controller can be mounted
so that the power supply is at the righthand side, or the controller can be rotated 90 degrees so that the
power supply is at the top. For either mounting, there must be sufficient space allowed for routing the
external wiring.

Four holes at the back of the enclosure are provided for surface mounting with screws. Use the steps in the
table below to mount the controller enclosure on a panel.

Step Action

1

2

Layout mounting hole patterns on panel according to dimensions shown in Figure 8. Or,
position controller enclosure on panel and use enclosure as a template.

NOTE: Rotate the mounting dimensions 90 degrees to mount the enclosure sideways with
the power supply at the top.

Drill and tap mounting holes for 1/4-20 (or M6) machine screws (supplied by us er).

3

16 UMC800 Controller Installati on and User Guide Release F

Position enclosure on panel so holes in enclosure align with holes in panel. Secure enclosure
to panel with 1/4-20 (or M6) machine screws using external tooth washers.

4/01

Enclosure mounting dimensions

Mounting and Wiring

Mounting the Controller

13.027

330.89

11.77

298.96

inches
Dimensions =

millimeters

_________

7.0

177.8

11.37

286.26

0.25

6.35

3.013

76.53

NOTE: Allow 7.0” (178 mm) depth to mounting dimensions for controller enclosure and cabling. To
mount the controller so that t he po wer supply is at the top, rotate the mounting dimensions 90 degrees.

Figure 8 UMC800 controller enclosure dimensions

Release F UMC800 Controller Installation and User Guide 17
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Mounting and Wiring
Plug-in Module Locations

Plug-in Module Locations

Common backplane

The controller backplane provides common connections for the power supply, CPU and I/O modules. All
modules are installed into the backplane in their assigned slots designated by the controller model number.
[See Controller model number (page 21).] The power supply and CPU occupy the slots on the right side of
the enclosure. See Figure 9. Slots for the I/O modules are numbered from 1 to 16 to be consistent with I/O
address assignment when using the PC control builder software.

Slots 1-8 (left to right) comprise the lower slots.
Slots 9-16 (left to right) comprise the upper slots.

9 10 11 12 13 14 15 16

I/O module identification

I/O modules consist of a Printed Wiring Assembly (PWA) and a color-coded terminal block. Each module
type is identified by a number label attached to a colored terminal block. Typically, red terminal blocks
indicate AC voltage inputs and outputs and black terminal blocks i ndicate low voltage modules. See Figure
10 for an example. Module type and terminal block identification are described in Table 6.

CAUTION

Do not switch the terminal boards and I/O module PWAs. The color and number designation
of the terminal boards should match the correct I/O module type.

I/O Module Slots

1 2 3 4 5 6 7 8

Figure 9 UMC800 controller plug-in slots

CPU

Power
Supply

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Mounting and Wiring

Plug-in Module Locations

I/O Module
PWA

Figure 10 I/O module PWA and terminal

Terminal
Block

+

OUT 4

_

!

+

OUT 3

_
+

OUT 2

_

mA
0-20

+

OUT 1

_

Table 6 I/O module identification

Module Type ID Number

Analog Input (AI) 1 Black 46190305-503
Analog Output (AO) 2 Black 46190314-503
Digital Input (DI) - Logic 3 Black 46190311-503
Digital Input (DI) - DC 4 Black 46190347-501
Digital Input (DI) - AC 5 Red 46190350-501
Digital Input (DI) - 16 point B Orange or Beige 46190353-501
Digital Outputs (DO) - Relay 6 Red 46190308-503
Digital Outputs (DO) - DC 7 Black 46190341-501
Digital Outputs (DO) - AC 8 Red 46190344-501
Digital Outputs (DO) - Higher

A Red 46190344-502

Current AC
± 15 Vdc pH Power Module C Black 51450921-501
Pulse/Frequency Input D Black 46190360-501

Terminal Block

Color

Part Number

Release F UMC800 Controller Installation and User Guide 19
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Mounting and Wiring
Plug-in Module Locations

I/O module limits

The controller backplane accommodates I/O module types, subject to the limitations as shown in Table 7.
Slot Locations identify the allowable locations in the controller for each I/O module type. Maximum
Allowed describes the maximum I/O configuration for each I/O type in a controller.

Table 7 I/O module installation limitations

I/O Module Type Slot Locations

(See Figure 9)

Universal Analog Input (ID: 1) 1 through 16 16 modules (64 points)
Analog Output (ID: 2) 1 through 10 4 modules (16 points)
Digital Input (ID: 3,4,5) 1 through 16 16 modules (96 points)*
Digital Input 16 point (ID: B) 14 through 16 3 modules (48 points)*
Digital Output (ID: 6,7,8) 1 through 8 8 modules (48 points)*
Digital Output (ID: A) 9 through 16 2 modules (12 points)*
± 15 Vdc pH Power Module (ID: C) 5, 6 2 modules (8 points)
Pulse/Frequency Input (ID: D) 1 through 16 16 modules (64 points)

Maximum Allowed

NOTE: Total combined I/O of all types is limited by the 16 available controller I/O slots.
* Total of 96 DI/DOs allowed for all types combined.

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Controller model number

The controller model number speci fied on your purchase order indicates the I/O module types and the
assigned slot location of each I/O module present in the controller.
modules are defined below.

Example of controller model number

Mounting and Wiring

Plug-in Module Locations

The number fields that identify I/O

Controller Model Number

I/O module types and controller
locations for . . . Slots 1 to 8 Slots 9 to 16

8001 - 000 - 0E - 01122300 - 56800000

So the number 01122300 - 56800000 indicates that the controller is equipped with I/O module types in the
following slot locations:

Controller

Slot #

1 Blank (0) 9 DI AC Input (5)
2 Analog Input (1) 10 DO Relay Output (6)
3 Analog Input (1) 11 DO AC Output (8)
4 Analog Output (2) 12 Blank (0)
5 Analog Output (2) 13 Blank (0)
6 DI Logic Input (3) 14 Blank (0)
7 Blank (0) 15 Blank (0)
8 Blank (0) 16 Blank (0)

I/O Module Type

(Module ID)

Controller

Slot #

I/O Module Type

(Module ID)

NOTE: The numbers (in parenthesis) that identify the I/O module types are defined in Table 6.

Release F UMC800 Controller Installation and User Guide 21
4/01

Mounting and Wiring
Plug-in Module Locations

Verify I/O module locations

The table below outlines the steps for identifying and recording the I/O module types in the controller.

Step Action

1

2

Controller

Slot No.

1
2
3

4
5

Verify that the module types installed in the controller card slots are correct according to the
controller model number. Refer to Table 6 to identify the module types.

Use to record the location, module type and signal type/range for each I/O module installed
in the controller.

NOTE  Module types should be installed in accordance with the limitations described in
Table 7.

Table 8 I/O module identification record

Signal Type/Range

I/O Module Type

(AI, AO, DI, DO, or PI/FI)

(mV, V, mA, T/C, RTD, Ohms, pH)*

Al Ch 1 Al Ch 2 Al Ch 3 Al Ch 4

Terminal Block

Color

6
7

8

9
10
11
12
13
14
15
16

* An Analog Input (AI) Module can be configured to accept multiple input types.

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Signal Wiring

I/O module wiring

Terminal blocks are installed to the front of the I/O modules for connecting field device wiring as shown in
Figure 11. Terminal blocks are color coded and numbered to identify the I/O module type. (See Table 6.)
The terminal blocks are removable so that I/O modules can be replaced without disconnecting the field
wiring from the terminal blocks. Wire gauge sizes 16 to 22 AWG can be used to connect to the terminal
blocks. The field wiring exits through rubber grommets at the top or bottom of controller enclosure. The
rubber grommets are removed by sliding the grommet forward with the terminal block and the attached
field wiring.

I/O Module
Identification

12
11
10

9
8
7
6
5
4

Mounting and Wiring

Signal Wiring

Locks

2

Field Wiring
Terminals

3
2
1

Locks

Figure 11 I/O module terminal block (all except 16 point DI)

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Mounting and Wiring
Signal Wiring

Analog input / analog output field wiring

Shielded twisted pairs are recommended (and required for CE approval) for analog input (AI) and analog
output (AO) module field wiring. If a cabinet shield termination point is not available, the optional shield
termination bracket may be used, (specify part number 51309814-501). The shield termination point is a
bracket attached at the top and/or bottom on the front of the controller enclosure. The wiring shields are
attached using the screws of the shield termination. Figure 12 shows the field wiring termination strip
attached to the bottom front of the enclosure.

Figure 12 Field wiring shield termination

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Analog inputs (module ID 1)

A universal Analog Input module accepts a variety of input signals from field devices as summarized in
Table 9. Figure 13 illustrates the terminal block connection s for the various inputs. See Specifications
section for more details on all I/O module specifications. One AI module can be configured to accept
multiple input types.

Table 9 Universal analog input module specifications

Specification Description

Input Types mV, V, mA, T/C, RTD, and Ohms
Number of Inputs 4 per module, up to 16 modules per controller (64 inputs)

Mounting and Wiring

Signal Wiring

RTD

RTD

RTD

RTD

Signal Source

Input Impedance

12

+

11

-

10

1

+

9

-

8
7

+

6

-

5
4

3

+

2

-

1

Thermocouple with cold junction compensation, for operation between 32 °F to
176 °F (0 °C to 80 °C)

Line resistance up to 1000 ohms, T/C, mV, mA, V
RTD Pt 100 3-wire connections, 40 ohms balanced max.

10 Megohms for T/C, mV inputs,
> 1 Megohms for volt inputs

Field Wiring

Channel 4

Thermocouple Input

+

T/C, mV, V

-

Current Input mA

4 to 20

mA

*

Source

+

-

Channel 3

Ground T er minal

* A 250 ohm res istor is required f or
the input range.

RTD Input (3 wires)

+

-

RTD

Ground Terminal

Channel 2

Channel 1

Ground Terminal

mV, V Inputs

mV or V

Source

Ground Terminal

+

-

Figure 13 AI module terminal block connections

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Mounting and Wiring
Signal Wiring

Field wiring for one pH sensor input (module ID C)

Figure 14 indicates the recommended wiring for one pH sensor input. Note that two analog input channels
are required, one for the pH sensor and one for temperature. Similar wiring may be used for additional
sensors. A UMC800 controller can accommodate 2 power modules for a total of up to 8 pH inputs.

UMC800 Controll er

Mod 1

Mod 4

pH 1 Sensor
Temp

pH 1 Sensor
mV

-

+

Analog Input
Module

Red/Black
Red
White

Orange

Black

COM

White/Black

(Unused)

Green

Blue

12

1

+

-

+

-

1

Jumper

12

C

-

C

+

-

C

+

-

C

+

1

UMC800 Shield Connector Kit
Part No. 51309814-501

Figure 14 Recommended wiring for one pH sensor input

Power Su pply Module

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Analog outputs (module ID 2)

The Analog Output (AO) module provides four outputs at 0 mA to 20 mA (configurable for 4 mA to
20 mA or any span between 0 mA to 20 mA). When not used for an analog output, an output channel may
be used to power a transmitter with 24 Vdc power. The controller will support up to 4 AO modules, for a
total of 16 outputs. Figure 15 shows the terminal connections for the AO module. See Specifications
section for details on all I/O module specifications.

Mounting and Wiring

Signal Wiring

12
11
10

9
8
7

Channel 4

2

Field Wiring

Load

Channel 3

Ground Terminal

4 to 20 mA Output

+

-

4 to 20 ma
Generator

Gnd

6
5
4

3
2

Channel 2

Channel 1

Fiel d Wiring

24 V

+

DC

Power

-

1

Gnd

ATTENTION

Channels not used as analog outputs can be used to supply a transmitter with 24 Vdc power.

Figure 15 AO module terminal block connections

Release F UMC800 Controller Installation and User Guide 27
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Mounting and Wiring
Signal Wiring

Digital inputs

Three types of Digital Input (DI) modules accept four types of input signals.

1. Logic Input (Module ID 3 and B)

2. DC Input (Module ID 4)

3. AC Input (Module ID 5)

4. Pulse/Frequency Input (Module ID D)
Each type is described on the following pages. Figure 16 shows the terminal block connections for all DI

modules. See Specifications section for details on all I/O module speci fications.

ATTENTION

16 Point Digital Input module (ID B) has 32 terminals. If you are using 2 wires per DI, use 22
gage wires so all 32 wires can fit through the rubber grommet in the controller case. See
Figure 16.

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Module B
Identifiable by
32 screws

2

+
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32

Each odd-numbered
terminal is internally
grounded.

Gnd

DI 16
DI 15
DI 14

DI 13
DI 12
DI 11
DI 10
DI 9
DI 8
DI 7

DI 6
DI 5
DI 4
DI 3
DI 2

DI 1

Module ID
#3, 4, or 5

12
11
10

Mounting and Wiring

Signal Wiring

DI 6

DI 5
9
8
7
6
5
4

3
2
1

DI 4

DI 3

DI 2

DI 1

Module ID B (16 DI)
Logic Input (Conta ct Closure)

For 2 wires per DI, must use 22-gage wire to fit 32
wires through rubber grommet on case.

R

Field Wiring

Dry SW

Module ID B (16 DI)
Logic Input (Contact Closure)

For 1 common wire for all DIs, use 16-22 gage wire.

Field Wiring

Dry SW

Gnd

+ VCC

R

Gnd

+ VCC

• One wire per DI. Each wire goes to
Marshalling field connector (user provided).

• One common wire from Marshalling field
connector to any ground connector on the
16 pt. DI terminal.

Marshalling field
connector

Figure 16 DI module terminal block connections

Logic

Logic

Module ID #3
Logic Input (Contact Closure)

Field Wiring

Module ID #4
DC Input (24 Vdc )

Field Wiring

+

24V

-

Module ID #5
AC Input (120/240 Vdc)

Field Wiring

Dry SW

L1

L2

R

Gnd

+ VCC

+ VCC

+

R

-

+ VCC

R

Release F UMC800 Controller Installation and User Guide 29
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Mounting and Wiring
Signal Wiring

Digital outputs

There are four types of Digital Output (DO) modules that provide three types of Off/On control.

1. Relay (alarm) output (Module ID 6) 46190308-503

2. DC output (Module ID 7) 46190341-501

3. AC output (Module ID 8) 46190344-501

4. AC high output (Module ID A) 46190344-502
Figure 17 shows the terminal block connections for the DC output and AC output DO modules. See

Specifications section for details on all I/O module speci fication s.

Module ID #6
Relay(Alarm) Output

Module ID
#6, 7, 8,
or A

12
11
10

9
8
7
6
5
4

3
2
1

Modul e ID A
AC Output (120/240Vdc)

Wiring same as module 8.

Maximum Load Cur rent:
Outputs

DO 1 – 4 @ .5A
DO 5 and 6 @ 2A

DO 6

DO 5

DO 4

DO 3

DO 2

DO 1

Field Wiring

L1

L2

Load

Module ID #7
DC IOutput (24 Vdc)

Field Wiring

+

24V

-

Load

Module ID #8
AC Output (120/240 Vdc)

Field Wiring

L1

L2

Load

Fuse

Fuse

R

VCC

Figure 17 DO module terminal block connections

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Mounting and Wiring

Signal Wiring

The Digital Output module with relay outputs (Module ID 6 ) contain jumpers to set the de-energized state
of the relay contacts. The relays are factory set to normally open (NO) for each output on the relay alarm
module, as shown in Figure 18.

To change the state of the contacts: Use a pair of needle-nose pliers and move the jumper from the location
NO (normally closed) to the location NC (normally closed).

Digital Output
Module

Normally Open
Contacts

NO

NC

NC6

S6

NO6
NC5

S5

NO5

NC4

S4

NO4
NC3

S3

NO3

NC2

S2

NO2
NC1

S1

NO1

Normally Closed
Contacts

12
11

10

!

9
8
7
6
5
4

NO NC

3
2

1

Figure 18 DO module relay contact setting

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Mounting and Wiring
Signal Wiring

Pulse input/frequency input module with digital outputs

Figure 19 shows the terminal block connections for Pulse/Frequency Input Module. See Specifications
section for details on all I/O module specifications.

ATTENTION

16 Point Digital Input module (ID D) has 32 terminals. If you are using 2 wires per DI, use 22
gage wires so all 32 wires can fit through the rubber grommet in the controller case. See
Figure 19.

Module ID - D
Identifiable by
32 screws

2

+
4
6
8
10
12
14
16
18
20
22
24
26
28
30
32

Each odd-numbered
terminal is internally
grounded.

Gnd

Input 1 +
Input 1 ­Input 2 +

Input 2 ­DO1 +
DO1 ­DO2 +
DO2 ­DO3 +
DO3 -

DO4 +
DO4 ­Input 3 +
Input 3 ­Input 4 +

Input 4 -

Figure 19 PI/FI module terminal block connections

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Pulse input/frequency input jumpers

The Pulse/Frequency Input Module with Digital Outputs (M odule ID D) contain jumpers to set the de­energized Input Filter Cutoff Frequency. All four inputs are factory set to 500 KHz as shown in Figure 23.
To change, use needle nose pliers and move the jumper(s) to the desired position. See the figure below for
the default positions and jumper settings for 100 KHz and 5 KHz.

4

6

1

9

0

3

6

0

-

5

0

1

Pulse/Frequency Input Board

OFF

JX1 -

JX2 -

ON

Mounting and Wiring

Signal Wiring

1

500KHz

2
1

100KHz

2
1

5KHz

2

JA1
JA2

JB1
JB2

Figure 20 PI/FI module input filter cutoff frequency setting

Pulse/frequency card wiring

The pulse frequency card input is designed to accept a contact closure type transmitter. The typical wiring
circuit is shown below.

+

-

Pulse Transmitter

MOSFET, Open Collector, or
Contact Closure drive.

V Supply (DC)

R

L

V Return (DC)

JC2
JC1

JD2
JD1

+

RT=1k

­+

Note: All puls e

-

frequency inputs
share a return
connection that is
common to all pulse /
frequency inputs on a
card.

Pulse / Frequency Input Card

Input Connections

Figure 21 Pulse/frequency input connections

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4/01

Mounting and Wiring
Signal Wiring

V supply

Choose a supply that is compatible with the environmental require ments o f your application. The supply
voltage must be within the requirement of both the transmitter and the pulse input card. Typically a low
cost 12 Vdc unregulated supply can be used in most applications provided in meets applicable regulatory
requirements. 1k ohm termination resistors (R
the internal resistor must meet pulse frequency card requirements. The circuit in Figure 21 provides for a
1 k ohm load resistor and a 12 V supply. The actual pulse voltage seen across the pulse \ frequency input is
divided by R
volts. For a 1 k ohm load the minimum V supply will be 3 V (R

V return

The pulse / frequency cards pulse inputs are optically isolated from other circuitry but share a common
isolated supply common. When multiple inputs are used the supply voltage returns will be connected to a
common reference internal to the pulse frequency card. The pulse / frequency cards digital outputs are
optically isolated from all inputs and each other.

R

L

The maximum sink current specified by the pulse transmitter specifies the minimum load resistance.
Typically R

) are built into the pulse frequency card. The voltage across

T

/(RL+RT) V

T

is within the range of 100 to 100k ohms. A 1 k ohm resistor is typically recommended.

L

= 6 V. The VIH minimum pulse threshold voltage for the pulse input card is 3

Supply

)/ RT = 6V.

L+RT

The transmitter often provides a selection for the pulse duration or width. The pulse input card internal R/C
filtering will attenuate short pulse widths. Below is a table for filter and pulse width settings for several
pulse freque nc y ran ge s.

Max Pulse Frequency Typical Filter Jumper Setting Pulse Width Range

100kHz 500 K Hz 2 uSec to 9 uSec
10kHz 100 K Hz 9 uSec to 90 uSec
1kHz 5 K Hz 180 uSec to 900uSec
100Hz 5 K Hz 180 uSec to 9mSec

(Vsupply = 12 Vdc, RL = 1 K ohm)
The minimum pulse frequency is 10 Hz regardless of the filter jumper settings.
The pulse frequency card input wiring requirements must be compatible with both the pulse frequency card

and the transmitter manufactures specifications. A typical transmitter will specify the maximum supply
voltage and the maximu m sink current.

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Pulse frequency card outputs

The pulse frequency card outputs are open collector drivers designed to drive a maximum of 100 mA. All
Pulse Frequency card digital outputs are optically isolated from each other. The maximum supply voltage
must not exceed 27 Volts dc.

Mounting and Wiring

Signal Wiring

V Supply (DC) 27 V Max

IL (100mA Max)

V Return (DC)

+

+

Pulse / Frequency Input Card

DO connections

Figure 22 Pulse/frequency card digital output connections

Release F UMC800 Controller Installation and User Guide 35
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Mounting and Wiring
Wiring Communication Links

Wiring Communication Links

Serial communications ports

The controller communicates through a number of serial ports. The CPU module contains two serial ports.
One is an RS 232 connection to a PC and another is dedicated for connection to the operator interface. The
CPU with optional communications features two additional RS 485 serial ports.

The serial port connectors on the CPU module are shown in Figure 23. Table 10 summarizes the
communication link connections to the controller and other reference data for wiring details.

OFFLINE

PROGRAM

RUN

Pin 1

Pin 9

POWER
LoBAT
FORCE
RUN

Repl ac e ba t ter y with T a di ra n T L5 10 1/ S

on ly. Us e o f ano t her ba tt er y ma y

pre se nt a ri s k of fi re or e x pl os i on .

BAT

CPU

See users guide for instructions.

CONFIGURATION

CONFIGURATION

Power
Supply

DISPLAY

Ope rat or Inter fac e

Connector for optional

RS 485 Serial Interface

COMM B COMM A

slave communications.

Connector for optional

RS 485 Serial Interface

master communications

Connector for PC

Interface cable

(Null Modem)

DISPLAY

Connector for

cable

COMM A

COMM B

Figure 23 Communication port connectors

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Mounting and Wiring

Wiring Communication Links

Table 10 Summary of communication link connections to controller

Communication

Link to . . .

PC or laptop (via
Null Modem cable
or via modem)

Operator interface RS 422

Modbus Link
(optional
communications
board)

Modbus Link
(optional
communications
board)

Link Type

RS 232

RS 485
(Half
Duplex)

RS 485
(Half

Duplex)

From Controller

Port

CONFIGURATION

(9-pin “D”
connector)

DISPLAY

(15-pin “D”
connector)

COMM A

(4-wire + shield or
2-wire shielded
with external
jumpers

COMM B

(4-wire + shield or
2-wire shielded
with external
jumpers

Connect

Cable

Up to 50 ft
cable lengths

(Supplied by
user)

10 ft or 50 ft
cable lengths
available.

Up to 2000 ft
cable lengths
(Supplied by
user)

Up to 2000 ft
cable lengths
(Supplied by
user)

To Port Reference Data

Serial port of PC. Null Modem

cable, 9-pin
Male/Female
See Table 11.

Modem: See
Remote Access
(page 44)

Terminal connector
of operator
interface.

Modbus
communications
and PC host.

Modbus
communications
and slave devices.-

See Table 12.

See Figure 26.

See Figure 26.

CONFIGURATION connector

The Configuration connector accommodates a 9-pin D-type Null Modem cable connection to the serial
RS-232 input of a PC or laptop computer. Table 11 describes the pinouts for the connector. See Figure 23
for the pin numbering. If you need to construct the cable, Table 12 shows the make up of the cable.

Table 11 Configuration connector pinouts

Configuration Connector Pinouts

(For Null Modem Cable)

Signal Name Terminal No.

DCD 1
RXD 2

TXD 3
DTR 4
GND 5
DSR 6

RTS 7

CTS 8

RI 9

Release F UMC800 Controller Installation and User Guide 37
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Mounting and Wiring
Wiring Communication Links

CONFIGURATION cable

Table 12 Null modem cable construction

PC Connector

9-Pin “D” Female

Pin Pin

2
3
5
4
6
7
8

UMC800

9-Pin “D” Male

2
3
5
4
6
7
8

Order part number -

51404755-501

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Installing ferrite clamp for CE compliance

This procedure ensures that unwanted radio frequency noise is filtered. It is r equired for CE compliance.

Parts needed

Part # Quantity Description

047260 1 Ferrite cable cla mp s
089037 2 Nylon cable ties

Installing ferrite clamp

Step Action

Mounting and Wiring

Wiring Communication Links

1
2

3
4

5

Disconnect all power to the instrument.
See Figure 24. Attach the ferrite clamp around all the wires as close to the Configuration port

terminals as possible (within ½” of the terminals). For maximum shielding you must minimize
the amount of unshielded exposed wire. The ferrite clamp should overlap or abut the cable
shield enclosing the wires.

Snap the ferrite clamp closed, making sure to not pinch the wires.
To prevent the ferrite clamp from sliding, attach cable ties around the wires snugly against each

end of the ferrite clamp.
Trim the cable tie but leave a “tail” of approximately 1”.

C

a

b

l

e

Terminals

Attach ties snugly
against each side of
the clamp.

Figure 24 Ferrite clamp installation

Release F UMC800 Controller Installation and User Guide 39
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Mounting and Wiring
Wiring Communication Links

DISPLAY connector (to operator interface)

The controller is connected to the operator interface through a 15-pin D-Type connector cable. One cable
end is connected to the DISPLAY connector of the controller. The other end connects to a 10-pin in-line
connector at the rear of the operator interface case. This cable end must be made, since some installations
may require the cable to be run through conduit. Table 13 shows the pinouts for the operator interface end
of the cable. Figure 25 shows the connector location at the rear of the operator interface.

Table 13 Operator interface connector pinouts

Operator Interface Connector Wiring

Signal Name Wire Color Terminal No.

Receive –
Receive +

Receive Shield
Transmit Shield

Transmit –
Transmit +

Signal Ground
Signal Ground

Outer Shield

- - - - - - - ­+24 Vdc *

+24 Vdc *

Black
White

Shield
Shield

Black
Red

Black
Green

Shield

- - - - ­Black

Blue

1
2

3

4
5

6

7
8

9

10

*

CAUTION: For 24 Vdc, make sure that the wiring is on terminals #9 and
#10. The CPU board may be damaged if the wiring is accidentally connected

to terminals #1 and #2.

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Connector location at the rear of the operator interface

551 Operator Interface

Rear

Connector Terminal Wiring
Signal Wire Terminal

Name Color Number
RX- Black 1

RX+ White 2
RX Shd. Shield ----- 3
TX Shd. Shield --­TX- Black 4
TX+ Red 5
Sig. Gnd Black ------ 6
Sig. Gnd Green --­Outer Shd. Shield 7
Not Used Not Used 8
+24 VDC Black 9
+24VDC Blue 10

552 Operator Interface

Rear

Connector Terminal Wiring

Signal
Name

+24VDC
+24VDC
Not Used
Outer Shield
24V Shield
Sig. Gnd. Shield
Sig. Gnd
Sig. Gnd
TX+
TX­TX Shd.
RX Shd.
RX+
RX-

Wire
Color

Blue
Black
Not Used
Shield
Shield
Shield
Green
Black
Red
Black
Shield
Shield
White
Black

Terminal
Number

10
9
8

7
6
5

4
3

2
1

Mounting and Wiring

Wiring Communication Links

Connector

for Cable

from Controller

Connector

for Cable

from Controller

1041 Operator Interface

Rear

Connector Terminal Wi ring
Signal Wire Terminal

Name Color Number
RX- Black 1

RX+ White 2
RX Shd. Shield ----- 3
TX Shd. Shield --­TX- Black 4
TX+ Red 5
Sig. Gnd Black ------ 6
Sig . Gnd Green --­Outer Shd. Shield 7
Not Used Not Used 8
+24 VDC Black 9
+24VDC Blue 10

Connector

for Cable

Connector

for Keyboard

from Controller

Figure 25 Terminal connections

Release F UMC800 Controller Installation and User Guide 41
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Mounting and Wiring
Wiring Communication Links

COMM A and B connectors (optional)

The CPU module equipped with the optional communicatio n board provides two additional RS 485
communications ports with Modbus RTU protocol support. COMM A port allows the UMC800 controller
to network with up to 31 other slave UMC800 controllers and devices on a Modbus link. COMM B port
allows the UMC800 controller to be a master to up to 16 slave UMC800 controllers and devices on a
Modbus link.

Figure 26 shows the COMM A and B connector wiring when using either a shielded twisted pair or 4-wire
shielded cable.

NOTE: When using the RS 485 communications, it is recommended that an RS 485 to RS 232 converter
(such as Black Box model IC901A) be used to interface with the host PC. Also, be certain that the Half
Duplex Turnaround Delay parameter for the converter set to 1 millisecond or less.

2-Wire

Shielded

Shield

Receive

Transmit

+
_

+

_

COMM A

Shield

Receive

Transmit

ATTENTION

Make sure you connect the correct polarity. If the TX+ and TX– connections are reversed from
the correct connections, an error message will be generated when attempting to do any
communications and the program then self-terminates.

+
_

+
_

Figure 26 COMM A and B port wiring (2-wire and 4-wire)

COMM B

Shield

Receive

Transmit

Shield

Receive

Transmit

4-Wire

Shielded

+
_

+

_

+
_

+
_

COMM A

COMM B

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RS 485 serial communications

When connecting the controller to a RS 485 communication link (see Figure 27), you must use termination
resistors at each end of the link. The following cables with the listed resistor values can be used for
connecting the controller.

RS 485 Cables: Belden #9271 (or equivalent) with 120 ohm termination resistors (2,000 ft. maximum)

Belden #9182 (or equivalent) with 150 ohm termination resistors (4,000 ft. maximum)

Computer

Mounting and Wiring

Wiring Communication Links

OFFLINE

RUN

PROGRAM

Host

CONFIGURATION

POWER
LoBAT
FORCE
RUN

RS232/RS485
Converter*

*RS 485 communications
requires termination resistors
at each end.

Figure 27 RS 485 port wiring (2 wire)

Controller with Optional
Communications Board

To other UMC800 Controllers*

Repl ac e batt er y wit h Ta dira n TL5 10 1/ S

BAT

only. Use of another battery may

present a risk of fire or explosi on.

See users guide for instructions.

DISPLAY

COMM B COMM A

_

100 - 240 V ~

50 / 60 Hz

100 VA MAX.

F 3,15 AT

250V

L1
L2 / N

Release F UMC800 Controller Installation and User Guide 43
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Mounting and Wiring
Remote Access

Remote Access

Overview

Remote controller access via dial-up modem is available via the communication setup. An external modem
is required at the controller and is connected to the standard RS232 configuration port (marked
“CONFIGURATION”). All functions of the Control Builder and User Utility pr ograms can be performed
over this link. Remote access functions include on-line monitoring, configuration upload and download,
and firmware upgrade.

Modem requirements

Most commercially available modems can be used with the UMC800 controller. The modem must have the
following capabilities:

• RS232 interface

• Auto answer

• Can operate at 9600 baud, 8 data bits, 1 stop bit, and no parity

• Hardware handshaking ca n be disabled

• Software handshaking can be disabled

• Data Terminal Ready (DTR) input can be disabled

• Result codes can be suppressed

• Echo can be disabled

• Must be equipped with non-volatile memory (NVRAM) so that settings that are configured using

command strings can be retained during a power-outage

• Must be able to load the NVRAM settings automatically on power-up

Cable requirements

You will need an interface cable to connect the modem to the DB-9 female connector (marked
“CONFIGURATION”) on the controller. If your modem has a 25-pin connector, be sure to use a DB-25 to
DB-9 modem cable.

TIP

The Null Modem cable used to directly connect a PC running Control Builder Software to the
controller may typically not be used to connect the PC to the modem or to connect the modem
to the controller.

If your modem requires command string configuration, you will need an interface cable to connect the
modem to your PC. Refer to your modem and computer documentation to determine this cable’s
requirements.

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Modem configuration

Before connecting a modem to the controller’s RS232 port (marked “CONFIGURATION”), the modem
must be configured with the following settings:

• Baud Rate = 9600

• Parity = None

• 1 stop bit

• 8 data bits

• No handshaking

• Ignore DT R

• Suppress result codes

• Suppress echo

• Auto answer

• Disable command recognition (only necessary if the modem has this capability)

Mounting and Wiring

Remote Access

Some of these settings may be settable via switches. Others may require command strings to be written to
the modem using a PC terminal program such as Hyperterminal. You will need to refer to your modem’s
documentation to make this determination. Those settin gs that are configured using command strings must
be saved to the modem’s non-volatile RAM (NVRAM), and the NVRAM must be configured as the profile
that gets loaded when the modem is powered up.

Most modems are equipped with auto-recognition to set the baud rate, parity, stop bits, and data bits. If
your modem has no means of setting these using switches, then most likely it is equipped with auto­recognition. To configure the port settings of a modem with auto recognition, do the following:

Step Action

1

Connect the modem to a PC.

2

Power up the modem.

3

Start up a PC terminal program such as Hyperterminal.

4

Configure the port for 9600 baud, no parity, 1 stop bit, and 8 data bits.

5 Establish communications with the modem. A common way of doing this is simply entering the

AT E1 Q0 command and seeing if the modem responds with OK.

Once you establish communication to the modem, its port settings are configured.

6

Save the port settings to the profile that gets loaded on power-up.

Release F UMC800 Controller Installation and User Guide 45
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Mounting and Wiring
Remote Access

Modem configuration examples

Below are procedures for setting up the following commercially available modems:

• 3Com US Robotics 56K Data/Fax External Modem

• Zoom 56K Dualmode External Modem

• Best Data 56SX Data Fax External Modem

• SixNet VT-MODEM Industrial External Modem

3Com US Robotics 56K Data/Fax External Modem

Step Action

1

Ensure that the switches are set to the factory settings:

Switch Setting Position Function

1 OFF UP Normal DTR operations
2 OFF UP Verbal (word) results
3 ON DOWN Enable result codes
4 OFF UP Displays keyboard commands
5 ON DOWN Disables auto answer
6 OFF UP Modem sends CD signal when it connects with another

7 OFF UP Loads Y0-Y4 configuration from user-defined

8 ON DOWN Enables recognition (smart mode)

modem

nonvolatile memory (NVRAM)

2

Connect the modem to a PC. If your computer’s RS232 port has a 25-pin connector, use a
DB-25 male to DB-25 female RS232 cable. If your computer’s RS232 port has a 9-p in
connector, use a DB-25 male to DB-9 female modem cable.

3

Power-up the modem.

4

Run a serial communication port program such as Hyperterminal.

5

Within the communication program, select the port to which the modem is connected.

6

Configure the port to these settings:

baud rate = 9600
data bits = 8
parity = none
stop bits = 1
flow control = none

7

In the program’s terminal window, type in the letters “AT” followed by the enter key. The
modem should give an OK response.

8

Power down the modem and disconnect it from the PC.

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Step Action

9

Set the modem switches to the following:

Switch Setting Position Function

1 ON DOWN Modem ignores DTR (Override)
2 OFF UP Verbal (word) results
3 OFF UP Suppresses result codes
4 ON DOWN Suppresses echo
5 OFF UP Modem answers on first ring
6 ON DOWN CD always ON (Override)
7 OFF UP Loads Y0-Y4 configuration from user-defined

nonvolatile memory (NVRAM)

8 OFF UP Disables command recognition (dumb mode)

Mounting and Wiring

Remote Access

10

11
12
13
14
15

Connect the modem to the RS232 port of the UMC800 using a DB-25 male to DB-9 male
RS232 cable. Null modem cable may not work.

Connect the modem to a telephone jack.
Power up the modem and the UMC800.
On a remote computer, run Control Builder software.
Setup Control Builder to dial the UMC800.
Verify that communications is established with the remote UMC800.

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Mounting and Wiring
Remote Access

Zoom 56K Dualmode External Modem

Step Action

1

Connect the modem to a PC. If your PC’s RS232 port has a 25-pin connector, use a DB-25
male to DB-25 female RS232 cable. If your PC’s RS232 port has a 9-pin connector, use a
DB-25 male to DB-9 female modem ca ble.

2

Connect power to the modem.

3

Power up the modem.

4

Run a serial communication port program such as Hyperterminal.

5

Within the communication program, select the port to which the modem is connected.

6

Configure the port to these settings:

baud rate = 9600
data bits = 8
parity = none
stop bits = 1
flow control = none

7

In the program’s terminal window, type in the letters “AT E1 Q0” followed by the enter key. The
modem should give an OK response.

8

9

10
11

12
13
14
15
16

Enter the following command string:

AT &Y0 &C0 &D0 &R1 &S0 &K0 S0=1

Modem should respond with OK.
Enter the following command string:

AT E0 Q1 &W0

Modem will not respond.
Power down the modem and disconnect it from the PC.
Connect the modem to the RS232 port of the UMC800 using a DB-25 male to DB-9 male

RS232 cable. Null modem cable may not work.
Connect the modem to a telephone jack.
Power up the modem and the UMC800.
On a remote computer, run Control Builder software.
Set up Control Builder to dial the UMC800.
Verify that communications is established with the remote UMC800.

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Best Data 56SX Data Fax External Modem

Step Action

1

Connect the modem to a PC. If your PC’s RS232 port has a 2- pin connector, use a DB-9 male
to DB-25 female modem cable. If your PC’s RS232 port has a 9-pin connector, use a DB-9
male to DB-9 female RS232 cable.

2

Connect power to the modem.

3

Power-up the modem.

4

Run a serial communication port program such as Hyperterminal.

5

Within the communication program, select the port to which the modem is connected.

6

Configure the port to these settings:

baud rate = 9600
data bits = 8
parity = none
stop bits = 1
flow control = none

7

In the program’s terminal window, type in the letters “AT E1 Q0” followed by the enter key. The
modem should give an OK response.

Mounting and Wiring

Remote Access

8

9

10
11

12
13
14
15
16

Enter the following command string:

AT &C0 &D0 &K0 &R1 &S0 &Y0 S0=1

Modem should respond with OK.
Enter the following command string:

AT E0 Q1 &W0

Modem will not respond.
Power down the modem and disconnect it from the PC.
Connect the modem’s serial cable to the RS232 port of the UMC800 using a DB-9 male to

DB-9 male RS232 cable. Null modem cable may not work.
Connect the modem to a telephone jack.
Power up the modem and the UMC800.
On a remote computer, run Control Builder software.
Set up Control Builder to dial the UMC800.
Verify that communications is established with the remote UMC800.

Release F UMC800 Controller Installation and User Guide 49
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Mounting and Wiring
Remote Access

SixNet VT-MODEM Industrial External Modem

Step Action

1

Connect the modem to a PC. If your PC’s RS232 port has a 25 pin connector, use a DB-9
male to DB-25 female modem cable. If your PC’s RS232 port has a 9 pin connector, use a
DB-9 male to DB-9 female RS232 cable.

2

Connect power to the modem. You will need to supply an external power supply with a DC
voltage between 10 and 30 VDC.

3

Power-up the modem.

4

Run a serial communication port program such as Hyperterminal.

5

Within the communication program, select the port to which the modem is connected.

6

Configure the port to these settings:

baud rate = 9600
data bits = 8
parity = none
stop bits = 1
flow control = none

7

8

9

10
11

12
13
14
15
16

In the program’s terminal window, type in the letters “AT E1 Q0” followed by the enter key. The
modem should give an OK response.

Enter the following command string:

AT &Y0 &C0 &D0 &R1 &S0 &K0 S0=1

Modem should respond with OK.
Enter the following command string:

AT E0 Q1 &W0

Modem will not respond.
Power down the modem and disconnect it from the PC.
Connect the modem to the RS232 port of the UMC800 using a DB-9 male to DB-9 male

modem cable. Null modem cable may not work.
Connect the modem to a telephone jack.
Power-up the modem and the UMC800.
On a remote computer, run Control Builder software.
Setup Control Builder to dial the UMC800.
Verify that communications is established with the remote UMC800.

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Power Supply Wiring

The power wiring is connected to the power terminals of the power supply in accordance with accepted
wiring practices and is summarized in Table 14 shows the terminal connections for the power wiring.

CAUTION

Mounting and Wiring
Power Supply Wiring

F 3,15 AT

250V

L1
L2 / N

Figure 28 Power supply terminal connections

Ground wiring

PROTECTIVE BONDING (grounding) of this controller and the enclosure in which it is installed shall be
in accordance with National Electrical Code (ANSI/NFPA 70) and local electrical codes.

Prepower checks

Before applying power to the controller file, verify that:

• The controller has been mounted in accordance with the instructions in this manual.

• The power wiring is correct and meets all local and national electrical codes.

Do not apply power to the controller at this time.

Table 14 Power supply wiring

Wire Designation Connect to Power

Terminal Designated

Hot L1 (+ DC)

Neutral L2 / N (– DC)

Ground

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Operation
Power Up / Power Down

Power Up / Power Down

Power-up

A sequence of checks are performed by the controller anytime power is applied to the controller. These
checks are a set of internal diagnostics that are completed in less than 10 seconds after power up and verify
the integrity of the controller hardware, the configuration database and firmware. Communication between
the operator interface and controller is established automatically after these checks are completed. All
outputs are OFF until addressed by the CPU.

Two start up routines are used for initializing the controller configuration.
A warm start is the default routine that is used to restart the controller operation. A warm start begins the

scan cycle of data points using all dynamic data retained from the previous legitimate scan.
A cold start (New start) initializes all control functio ns to their default initial state, (if default output

values are defined in the configuration). If defined, these values are used as the starting values for
controller operation.

Operation

Status indicators on the CPU module consist of four LEDs that indicate normal operation and diagnostic
fault conditions. See Status Indicators (page 59).

When power is applied to the controller, it will power up and initialize to the mode determined by the mode
switch setting on the CPU. See Mode control (page 53) for further information.

Power-down

The controller does not require the configuration to be reloaded when power is restored after a power loss
or power down. During a power interruption, the controller configuration is maintained in batter y-backed
RAM and a flash PROM on the CPU module. When the controller power is restored, and provided that the
battery power to the CPU RAM is not interrupted, the controller will perform a warm start. However, if
battery power to the RAM is interrupted, the controller configuration (whic h was last stored in the flash
PROM on the CPU), will be restored to the RAM when controller power is restored and then the controller
will perform a cold start.

CAUTION

Controller configuration is stored in RAM as well as the flash PROM on the CPU. However, if
you make changes to the configuration while the controller is in Run mode, the changes are
stored in RAM and not in the flash PROM. Therefore, if battery power is interrupted to RAM
during a power down condition, the configuration changes will be lost since controller
configuration will be restored from flash PROM.

Also, the real time clock will need to be set if battery power is interrupted during a power down
condition.

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Operational Modes and Controls

There are three operational modes defined in the UMC800 to provide safe operating environments for users
to implement changes and perform tasks on the controller and operator interface.

1. PROGRAM Mode

2. RUN Mode

3. OFFLINE Mode
Safeguards are built into the operating system to prevent conditions that could otherwise cause process

upsets or equipment malfunctions.

PROGRAM mode

The Program mode is used to download controller configuration files that contain signal flow and
processing details of the control configuration. When the contro ller is set to Program mode, all input signal
processing is stopped and all output signals and logic status are held at their last values. Also, DO function
blocks that are configured as Time Proportional Outputs (TPOs) are turned off.

When the controller is switched from Program mode to Offline or Run, the controller performs a cold start
and controller configuration is b acked up to flash PROM.

Operation

Operational Modes and Controls

RUN mode

The Run mode is used for norma l operation of the control system. All I/O processing is active and operator
actions are supported.

OFFLINE mode

The OFFLINE mode is used to download controller files such as setpoint profiles, recipes and data storage
files. Calibration of I/O modules and setting the real-time clock ca n also be performed with the controller in
the OFFLINE mode. When the controller is set to OFFLINE mode, all input signal processing is stopped
and all output signals and logic status are held at their last values. Also, DO function blocks that are
configured as Time Proportional Outputs (TPOs) are turned off. When the controller is switched from
OFFLINE mode to RUN, the controller performs a warm start.

Mode control

The controller mode can be set and changed in a number of ways (with certain restrictions) by:

1. A manual switch located on the CPU module of the controller. OFFLINE – RUN – PROGRAM).

See Table 15.
The switch on the controller CPU is a “pull and set” locking toggle that allows you to manually
switch the controller to one of the three operational modes. When the switch is set to either RUN or
OFFLINE, the mode can be overridden and changed by a command through the Configuration port.
However, when the manual switch is set to PROGRAM, the mode cannot be overridden.

CAUTION

The manual switch on the controller CPU module always determines the mode (PROGRAM,
RUN or OFFLINE) by reading the position of the switch when power is applied to the
controller. The controller will power up and initialize to the state of the manual switch position,
regardless of the controller mode before the controller was powered down.

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Operation
Operational Modes and Controls

2. From the Operator Interface.

Mode changes can be made from SET MODE display or the Calibrate AI and AO displays of the
operator interface with certain restrictions. When the manual switch is set to PROGRAM, you cannot
change the mode to RUN or OFFLINE using the operator interface. The operator interface is active in all
modes.

3. Through the CONFIGURATION Port.

A PC, running the Control Builder software, connected to the Con fi guration port can initiate mode
changes to the controller. The control builder places the controller in PROGRAM mode when
downloading files to the controller.

Restrictions on mode control

Mode control of the controller has the following restrictions:

• When the controller manual switch is set to RUN, the mode can be changed to OFFLINE or PROGRAM

by commands from the configuration port or the operator interface.

• When the manual switch is set to OFFLINE, the mode can be changed to PROGRAM by commands

from the configuration port or the operator interface. The mode cannot be changed to RUN from the
configuration port or the operator interface.

• When the manual switch is set to PROGRAM, no mode changes can be made by commands from the

configuration port or the operator interface.

Table 15 summarizes the mode change interactions and restrictions.

Controller
Mode
Switch

CPU Module

OFFLINE

RUN

PROGRAM

POWER
LoBAT
FORCE
RUN

Replace battery with Tadiran TL5101/S

only. Use of another battery may

present a risk of fire or explosion.

See users guide for inst ruc tions.

BAT

CONFIG U RA TION

_

DISPLAY

100 - 240 V ~

50 / 60 Hz

100 VA MAX.

Figure 29 Controller mode switch location

54 UMC800 Controller Installati on and User Guide Release F

4/01

Operational Modes and Controls

Table 15 Controller mode switch summary

Operation

Controller Mode Manual

Switch setting

RUN

OFFLINE

PROGRAM

through the Configuration Port or Operator Interface

Unrestricted mode changes.
The mode selected via the Configuration port or operator interface

overrides the controller manual mode switch position.
Can override OFFLINE mode to set controller to PROGRAM mode.
No mode changes can be made.

Setting mode switch to PROGRAM and then to RUN

Setting the controller mode switch to PROGRAM and then to RUN forces t he controller to perform a cold
start and other actions depending upon the condition of the database RAM.
changed from PROGRAM to RUN, the controller verifies that a valid database confi guration is present in
RAM before starting control loops.

So that,

If . . . (Condition of RAM) Then . . . (Controller Action)

A valid database configuration is present in RAM, Configuration is written to flash PROM. (User-

Database configuration in RAM is found to be bad,
but the configuration in flash PROM is good,

Mode Control

When the mode switch is

defined variables are initialized to zero.)
RAM is restored from the flash PROM that

contains the configuration values from the last
cold start.
[See CAUTION in Power Up / Power Down
(page 52).]

If the database configuration is found to be bad in
both RAM and flash PROM,

Controller is set to a null default configuration.
A system diagnostic INVALID CONFIG. is
generated.

In all cases the controller performs a cold start when the controller mode is set to PROGRAM and then to
RUN regardless of what method is used to change the mode.

Whether the mode was set through the

Configuration port or the operator interface, this action causes the PROGRAM mode to be cleared.
Additionally, setting the mode switch to PROGRAM and then RUN allows you to c hange the controller
mode if communications were disconnected to the Configuration port or operator interface while the
controller was still in PROGRAM mode.

Release F UMC800 Controller Installation and User Guide 55
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Operation
File Downloading

File Downloading

Downloading configuration files, recipes and other files to the controller can be accomplished two ways:

1. Download from a PC or other device connected the Configuration port (serial port) of the controller.

2. Using the operator interface to download files stored on a floppy disk.

These files include recipes,

setpoint profiles and data storage files.

There are mode restrictions on the downloading of certain configuration files. For example, the controller
must be in the Program mode before downloading a controller configuration file.

(Program mode is set

using either the controller manual mode switch, the SET MODE display of the operator interface or issuing
a command to the controller through the Configuration port.)

Downloading recipe information and read/write of specific parameters is permitted when the controller is in
the Program mode, as well as the Run or Offline modes. See Table 16 for a file downloading summary.

Table 16 Controller downloading summary

Downloading . . . Permitted When Controller is in . . .

PROGRAM Mode RUN Mode OFFLINE Mode
Controller Configuration Files
Setpoint Profiles / Setpoint

Schedule
Recipe Files
Data Storage Configuration Files
Data Storage Non-volatile

parameters

Yes No No
Yes Yes Yes

Yes Yes Yes
Yes No Yes
Yes Yes Yes

Also, there are mode restrictions for these procedures . . .

Calibration
Real-time Clock Change

56 UMC800 Controller Installati on and User Guide Release F

Yes No Yes
Yes Yes Yes

4/01

Download via CONFIGURATION port

A downloading tool in the control builder software can be used to download configuration files to the
controller. The downloading tool first verifies that a valid configuration file exists for the controller.
a dialog box asks if you want to set the controller to Program mode in preparation for downloading.
configuration file is verified to be valid, then the existing controller configuration in the controller’s
memory is deleted before the new configuration is downloaded.

Operation

Code Download

Next,

If the

A download dialog box appears on the PC after a successful file download to the controller.
completion of the download, a command is sent to set the controller to Run mode.

Download via floppy disk

The optional floppy disk drive allows the user to download configuration files stored on a floppy disk to the
controller using the operator interface.
store controller configuration files.
configuration files in the controller.
interface display.

Downloading restrictions are noted in Table 16.

File uploads

Controller configuration files, setpoint profiles and recipe files can be uploaded for storage and archiving to
a floppy disk as well as to the PC.
pull-down menu of the control builder.
menu selections for storing the files to disk.

Code Download

Controller firmware upgrade

In order to implement new features for controller operation or correct any software bugs, an upgrade of the
controller firmware may be required. The User Utility software program contains the code download utility
that allows a newer version of the controller firmware to be loaded into the CPU.

Upon

The DISK UTILITIES display provides menu selections to load and

The controller must be in the Program mode in order to load

Successful download status and failures are indicated at the operator

Using the PC, the Upload function is accessed from the Communications

At the operator interface, the DISK UTILITIES display contains

CAUTION

Before performing a code download:

• Perform a backup of all controller configuration files.

• Be certain that the controller does not show a low battery (LoBatt) diagnosti c.

After the download is successful reload the controller’s configuration files, recipes, profiles and
schedules.

Controller code download in the user utility

A PC running the user utility is connected to the controller’s Configuration port. The code download utility
is accessed from the Maintenance pull down menu.

Refer to the UMC800 User Utility User’s Guide and

on-line help for more details on performing the download.

Release F UMC800 Controller Installation and User Guide 57
4/01

Operation
Warm Start / Cold Start

Warm Start / Cold Start

Housekeeping and diagnostic routines are performed during power up sequence of the controller and prior
to the controller microprocessor starting normal scan processing.
OFF and all analog outputs are held to their zero output states.

After this activity, the controller may perform either a cold start or a warm start of the controller
configuration.

Warm start

Warm start is the default mode of start-up.

During this sequence all logic outputs are

A warm start begins the scan cycle with all dynamic data retained from the previous valid scan.
start occurs after a power up sequence with the configuration database integrity in RAM being verified.
warm start is initiated when the controller mode is set from Offline mode to run.

Cold start

A cold start initializes all functions to their default initialized states.
these values are used as the starting values for restart of the controller.

A cold start is performed when:

• A file download is performed through the control builder program.

• The mode is set from PROGRAM to RUN through the SET MODE display of the operator interface.

• Setting the controller manual mode switch from PROGRAM to OFFLINE or RUN. In this case, the

• The configuration database in RAM is found to be invalid during power up sequence.

Scan rates

The analog input scan rate is a function of the total number of configured inputs in the controller as well as
the number and type of configured function blocks. Table 17 shows the fastest scan rate time for the
number of analog input cards, although the actual scan rate will be the slower of either the analog input rate
or the function block execution rate. Analog outputs are always scanned at the analog input scan rate, as
well as function blocks and digital I/Os that are not configured for fast logic. Function blocks and digital
I/Os that are configured for fast logic are updated every 100 milliseconds.

A warm

A

If default output values are defined,

controller always performs a cold start.

Table 17 Scan rates per inputs configured

Number of analog input cards Time to complete one full

scan

(in milliseconds)

1 333
2 500
3 700
4 900
5 1100
6 1300
7 1500

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Status Indicators

Operation

Status Indicators

Number of analog input cards Time to complete one full

scan

(in milliseconds)

8 1700

9 1900
10 2100
11 2300
12 2500
13 2700
14 2900
15 3100
16 3300

Status LEDs

Four LEDs on the CPU module (shown in Figure 30) indicate the operating status of the controller and are
described in Table 18.

POWER

LoBAT
FORCE
RUN

NOTE: See Table 20 for the details of the indications and their meaning.

Table 18 Controller status LEDs

Designation State Indication

Steady on Power is applied to the controller backplane.

Blinking

On The CPU battery is low and needs replacement.
On One or more function block output values have been forced.
On Controller is in RUN mode.

Blinking Controller is in OFFLINE mode

Off Controller is in PROGRAM mode.

Diagnostic indication. See NOTE.

OR

If POWER LED is blinking a fault has been detected in
controller. See NOTE.

Release F UMC800 Controller Installation and User Guide 59
4/01

Operation
Status Indicators

Controller
Status
Indicators

CPU Module

OFFLINE

PROGRAM

POWER
LoBA T
FORCE
RUN

Repl ac e ba ttery with Ta di ra n T L5 101/ S

only. Us e of another battery may

prese nt a ris k of fire or explosion.

BAT

RUN

CONFIGURATION

See users guide for instruct ions.

DISPLAY

_

100 - 240 V ~

50 / 60 Hz

100 VA MAX.

Controller Status

The status of various controller parameters can be viewed through a number of displays.

1. The operator interface features a CONTROLLER STATUS display listing the status of various

parameters and is accessed from the UNIT SETUP display on the operator interface.
Operator Interface User Guide for more details on the Controller Status display.

2. The User Utility program contains a Controller Diagnostic Summary window listin g numerous

operating parameters and communication status. See UMC800 User Utility User’s Guide and the on­line help for more details on the Controller Diagnostic Summary window.

Alarm and status blocks

Additional controller status parameters can be monitored through the Analog System Status and Fast Logic
System Status blocks.
blocks can be wired to alarm groups and inputs to other function blocks.
battery, hardware integrity, communications failure, and function block c ycle times are monitored by these
status blocks.

See document 51-52-25-64 UMC800 Function Block Reference Guide for more details on

these status blocks.

Figure 30 Controller status LEDs

See UMC800

These blocks are configured using the control builder. Outputs from these status

Controller parameters such as low

60 UMC800 Controller Installati on and User Guide Release F

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RS 485 Port Configuration (Communication Board Option)

RS 485 Port Configuration (Communication Board Option)

COMM A and B ports

UMC controllers equipped with the optional communications board feature two RS 485 serial
communications ports (COMM A and COMM B) on the CPU module.
port connectors. See Wiring Communications links, Page(36) for more details on the port wiring. The
controller firmware supports Modbus RTU protocol for the ports.

The COMM A and COMM B ports must be set up so that the controller can communicate when connected
to a communication link.
program.

The Communications screen in the operator interface for COMM A is used to enable the port, set

the device (station) address of the controller and set the baud rate. The COMM B screen is used to set the
baud rate.

See UMC800 Operator Interface User Guide for details on communications port setup. See

UMC800 User Utility User’s Guide and the on-line help for more details on setting up the COMM ports.

COMM port status

COMM A status can be checked through the COMMUNICATIONS menu item on the operator interface.
COMM B status can be monitored with the User Utility. Slave device statuses can be viewed after loading
a configuration into User Utility via upload or floppy disk. Slave devices must first be enabled through the
operator interface COMMUNICATIONS menu item or the User Utility.

Set up is accomplished through the operator interface or the user utility software

See Figure 31 for location of the

Operation

CPU Module
with Optional
Communications
Board

COMM A

Port

COMM B

Port

POWER
LoBAT
FORCE
RUN

on.

n TL5 10 1/S

ry may

plosi

te

t
ba

Tadi ra

er
th

y with

batt er

a risk of fi re or ex
nt

ace

. Use of ano

pl

ly

prese

Re

on

BAT

.

nstr uct ions

de f or i
ui
g
rs

See use

DISPLAY

COMM B COM M A

_

100 - 24 0 V ~

50 / 60 Hz

100 VA MAX.

F 3,15 A T

250V

L1
L2 / N

COMM A and B shown with 2-wir e connections. See Wiri ng Communica tions links, Page(36) for 4-wire
details.

Figure 31 COMM A and B ports on CPU module

Release F UMC800 Controller Installation and User Guide 61
4/01

Operation
RS 485 Port Configuration (Communication Board Option)

62 UMC800 Controller Installati on and User Guide Release F

4/01

Overview

This section covers procedures in the maintenance, calibration and replacement of the controller and its
components.

Maintenance to the controller consists of the following procedures:

• Routine maint enance

• Calibration of I/O modules. (The backplane is factory calibrated only.)

• Field replacement of controller components

Warranty

• Warranty repair is by board replacement.

• Non-warranty service provides for field repair at the board level with option to return to factory for

repair.

Maintenance

Overview

Maintenance

Servicing

The power supply, CPU, and all I/O modules plug into the backplane for easy removal and replacement.
The I/O modules can be replaced without removal of the field wiring from the terminal screws.

The battery is accessible for easy replacement while the controller file is powered and operational to
prevent loss of configuration data.

CAUTION

TO PRESERVE THE CONTROLLER CONFIGURATION PRIOR TO PERFORMING ANY
REPLACEMENT PROCEDURES OR REMOVING POWER TO THE CONTROLLER:

• Be certain that the LoBatt LED is OFF. (MEMORY – LOW BATTERY diagnostic is not
active.)

• Force a cold start of the controller by setting the manual mode switch on the controller to
PROGRAM and then to RUN and allow the controller to complete its start up sequence.
Controller configuration files will be backed up to the flash PROM on the CPU

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 de­energize unit before servicing.

Release F UMC800 Controller Installation and User Guide 63
4/01

Maintenance
Routine Maintenance

Routine Maintenance

Controller maintenance

Normal routine maintenance of the controller is not necessary other than a periodic physical inspection of
the controller enclosure and wiring for any signs of deterioration or dust and dirt.

Battery replacement

Replace the battery located on the CPU when the
indicated.
RAM and the real time clock.

Also, It is recommended that the battery be replaced once a year to ensure back up power for the

Refer to procedure in Replacing the battery (page 73) for specific

instructions.

LoBATT LED lights o r the low battery diagnostic is

64 UMC800 Controller Installati on and User Guide Release F

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Controller Calibration

ATTENTION

All Analog Input (AI) and Analog Output (AO) modules are factory calibrated to 0.1% accuracy.
If this accuracy is sufficient for your applications, there is not need to recalibrate the modules.
If greater accuracy is required, the field calibration procedures will provide a 0.05% accuracy.

Please keep in mind that if you field calibrate AI or AO modules, you may have to recalibrate
these modules after performing certain replace ment pro cedure s. [See Replacement
Procedures (page 70).]

Calibration overview

Field Calibration of AI and AO modules in the controller is accomplished through either the operator
interface or the user utility program.

• Using the operator interface – Calibration displays are accessed from the UNIT SETUP display and

provide menu selections and display prompts that guide you through the desired calibration procedure.

• Using the user utility – Calibration dialog windows are accessed through menu selections in the

Maintenance me nu.

Maintenance

Controller Calibration

Analog Input modules can be calibrated to a number of references.

1. Calibration using 0% and 100% reference values applied at the terminal blocks of each module

channel.

2. Copying calibration values from one module channel to another. For example, you can copy the

calibration from one channel of a AI module to another channel of the same module, or to a channel
of a different AI module.

3. Calibration of the cold junction compensation references.

4. Restoring factory calibration values.
Analog Output modules also can be calibrated using measured values from the channel outputs, or they

can be restored to the initial factory calibration.

Release F UMC800 Controller Installation and User Guide 65
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Maintenance
Controller Calibration

Factory calibration

Factory calibration of controller components is performed before shipment to 0.1% accuracy. Calibration
values are contained in a number of the controller components, namely: the CPU, Backplane, and AI and
AO modules.

Figure 32 shows the various components in which calibration data is stored.

• Calibration functions and parameters for the user interface are stored in memory on the CPU.

• Each AI module contains two (2) cold junction compensation (CJC) references that are factory

calibrated. Factory calibration data for the CJC references is stored in a non-volatile memory on the AI
module.

• Field calibration values for the AI modules (both zero offset and span calibration and CJC reference

values) are stored on the CPU.

• Factory calibration values (zero offset and span corrections) for AO mod ules are sto r ed in non-volatile

memory on the AO module and can be changed only if the write protect jumper is not cut. See Write
Protect Jumper ST1.

• The gains and offsets of the preamp are factory calibrated and the calibration data is stored in a non-

volatile memory on the backplane. No field calibration of these values is possible.

Write Protect Jumper ST1

ATTENTION

A jumper (ST1) on the AO module PWA can be cut to prevent changes to calibration values.
This will write protect the AO and prevent further calibration of these values .

AI Module

AI01
AI02

CJC Factory

Calibration

AI03

Values

AI04

AO Module

AO01
AO02
AO03
AO04

ST1

CJC

Factory
& Field

Calibration

Values

CJC

CPU

Field

Calibration

Values

(AI and CJC)

in Battery-back ed RAM

Backplane

Factory Calibrated

Preamp Gains and Offsets

(for AI and CJC)

Calibration

Function

Calibration

User Interface

Figure 32 Controller components that contain calibration values

66 UMC800 Controller Installati on and User Guide Release F

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Field calibration

Field calibration of controller components is limited to AI modules and AO modules. Individual channels
of the modules can be calibrated at 0% and 100% of their range. Individual channels can be calibrated at a
single point within the range through zero offset (bias) adjustment.

Calibration procedures

Calibration routines are initiated from either the operator interface or a PC running the user utility program
by first placing the controller in the Program or Offli ne mode. This can be done manually at the Controller
or through the Calibration displays. Calibration displays are accessed from the UNIT SETUP display of the
operator interface or under the Maintenance menu of the user utility.

Refer to the UMC800 Operator Interface User Guide and the UMC800 User Utility User’s Guide for
details on these and other calibration procedures.

AI module calibration

Selecting the CALIBRATE AI lists a number of calibration functions you can perform.
Selecting the CALIBRATE AI CHANNEL allows you to specify the AI module and channel in which to

calibrate. When you Select Input, you must apply a 0% reference value to the terminal block of the module
channel. See Figure 33 for terminal connection points. Then select Calibrate 0% Input to start the
calibration routine. After calibration of 0% value is completed, apply a 100% range value to the channel
input terminals and then begin the calibration routine for 100% input.

Maintenance

Controller Calibration

ATTENTION

Handheld calibrators do not work with the UMC800 when calibrating RTDs because they are
resistance simulators with active components, not actual resistors.

When 100% range value calibration is completed, the controller compares the new 0% and 100% range
values against the current 0% and 100% values. If the span of the 0% and 100% readings is less than 20%
of the sensor range, the new values are rejected and the current calibration is retained.

Release F UMC800 Controller Installation and User Guide 67
4/01

Maintenance
Controller Calibration

Thermocouple Input

+

-

Ground Terminal

mV, V Inputs

mV or V

Source

Ground Terminal

+

-

T/C, mV, V

Current Input mA

4 to 20

mA

Source

Ground Te rminal

* A 250 ohm resistor is required for
the input range.

+

*

-

RTD Input (3 wires)

+

-

RTD

Ground Terminal

RTD

RTD

RTD

RTD

12

+

11

-

Channel 4

10

1

+

9

-

8

Channel 3

7

+

6

-

5

Channel 2

4

3

+

2

-

Channel 1

1

Figure 33 AI module terminal block

Other AI module calibration selections

Additional calibration selections allow you to perform other AI module calibration procedures:

• CALIBRATE CJ TEMP – for calibrating the two Cold Junction (CJ) references on the AI module

• COPY CALIBRATION – for copying calibration values from one AI module channel to another

• RESTORE AI FACTORY CAL – to restore AI module channels to their factor y calibration

• RESTORE CJ FACTORY CAL – to restore CJ reference to their factory

AO module calibration values

Two calibration selections are accessible under the CALIBRATE AO menu selection

1. CALIBRATE AO CHANNEL – to calibrate the zero offset and span values of the AO module

channels to user-defined values.

2. RESTORE AO FACTORY CAL – to restore factory calibrated to an AO module channel.
The AO module contains a wire jumper (labeled ST1) on the PWA. Cutting this jumper will prevent any

changes to initial calibration values of the module and prevent any further field calibration. See Figure 34
for the location of the jumper. More details on module calibration are given in the UMC800 Operator
Interface User Guide and the UMC800 User Utility User’s Guide.

68 UMC800 Controller Installati on and User Guide Release F

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Wire Jumper ST1

Maintenance

Controller Calibration

ST1

Analog Output

Module

Figure 34 AO module jumper ST1

+

OU T 4

_

+

OU T 3

_
+

OU T 2

_

0-20mA

+

OU T 1

_

!

Release F UMC800 Controller Installation and User Guide 69
4/01

Maintenance
Replacement Procedures

Replacement Procedures

The following tables outline the procedures for replacement of the controller components. Field
replacement is limited to the Printed Wiring Assembly (PWA) level. Use Figure 35 to locate controller
components for replacement.

F 3,15 A T

250V

L1
L2 / N

Power
Supply

Battery
Compartment

Power
Supply
Fuse

CPU Module

I/O Modules

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2

1

12
11
10

9
8
7
6
5
4

3
2
1

12
11
10

9
8
7
6
5
4

3
2

1

OFFLINE

RUN

PROGRAM

POWER
LoBAT
FORCE
RUN

Replace battery with Tadiran TL5101/S

only. Use of another battery may

present a risk of fire or explosion.

See user’s guide for instructions.

BAT

CONFIGURATION

_

100 - 240 V ~

DISPLAY

100 VA MAX.

COMM B COM M A

50 / 60 Hz

Backplane

Figure 35 Controller components and location

70 UMC800 Controller Installati on and User Guide Release F

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Maintenance

Replacement Procedures

CAUTION

TO PRESERVE THE CONTROLLER CONFIGURATION PRIOR TO PERFORMING ANY
REPLACEMENT PROCEDURES OR REMOVING POWER TO THE CONTROLLER:

• Be certain that the LoBatt LED is OFF. (MEMORY – LOW BATTERY diagnostic is not
active.)

• Force a cold start of the controller by setting the manual mode switch on the controller to
PROGRAM and then to RUN and allow the controller to complete its start up sequence.
Controller configuration files will be backed up to the flash PROM on the CPU.

• When powering up the controller, the controller performs a warm start provided that the
battery power to the RAM has not been interrupted. If battery power to the RAM has been
interrupted, the controller performs a cold start at power up and,

− The controller real time clock setting is lost and must be reset.

− Any field calibration values to the AI modules and CJ references are lost. If AI modules or

CJ references were required to be field calibrated to achieve greater than 0.1 %
accuracy, you must recalibrate those modules.

• If the CPU module is replaced, a valid configuration file must be downloaded to the
controller. Also field calibration of the AI module and the CJ reference are lost. If greater
than 0.1 % accuracy is required for the AI module or CJ reference, you must field calibrate
the module.

Release F UMC800 Controller Installation and User Guide 71
4/01

Maintenance
Replacement Procedures

Replacing the power supply fuse

The power supply input circuit is protected with a fuse. Use the steps in the table below to replace the fuse
on the power supply module.

Step Action

1 Remove power from the controller.
2

Locate the fuse holder located on the power supply module. See Figure 36.

3

Using a slotted screwdriver, remove the fuseholder cap by rotating it counterclockwise.

4

Replace the fuse with the proper size and type.

• For 100-240 V supply: Size 5x20, F 3.15 A Time Delay 250 V, or equivalent.

• For 24 V supply: Size 5x20, 6.3 A Slow Blow, or equivalent.

5

Replace the cap by pressing in and rotating it clockwise with the screwdriver.

CPU
Module

CPU Battery
Location

POWER
LoBAT
FORCE
RUN

n TL5101/S

ry may
te

t
ba
er

th

. Us e o f ano
ly

Replac e batt er y with Ta di ra

on

BAT

.

on.
plosi

nstruct i o ns

de for i
ui
g
rs

a risk of fire or ex
nt

prese

See use

PLAY

_

100 - 240 V ~

DIS

50 / 60 Hz

100 VA MAX.

COMM B COMM A

F 3,15 A T

250V

L1
L2 / N

Power
Supply

Fuse Holder

Figure 36 Power supply fuse and CPU battery location

72 UMC800 Controller Installati on and User Guide Release F

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Replacing the battery

A lithium battery is used as a keep alive voltage for the volatile memory (RAM) that contains the controller
configuration. The battery is installed in a compartment on the CPU module. Follow the steps in the table
below to replace the CPU battery.

CAUTION

The battery used in this device may present a risk of fire or chemical burn if mistreated. Do not
recharge, disassemble, heat above 212 °F (100 °C), or incinerate. Replace battery with
Tadiran TL-5101/SBP only. Use of another battery may present a risk of fire or explosion.

Step Action

Maintenance

Replacement Procedures

1
2

3

4
5

Locate the battery and the battery compartment location on the CPU module. See Figure 36.
Using a Phillips-head screwdriver, loosen the screw and remove the battery compartment

cover.

For the standard CPU module –

• Using a screwdriver, insert it through the screw hole on the front and carefully pry the

battery out of its holder. Carefully remove battery from the holder.

For the CPU module option –

• The battery holder is contained on the battery compartment cover. See figure. Carefully

remove battery from the holder.

Battery Compartment Cover

Battery

- +

Observing the correct polari ty, insert a new battery into the holder.
Verify that the LoBATT LED is off.
If LED is lit, the battery may installed incorrectly. Check polarity of battery and reinstall, if

necessary.

6

Replace the compartment cover and secure with the screw.

NOTE: I f controller power is restored and the battery-backed RAM has failed, field calibration of the AI
modules must be performed if greater than 0.1% accuracy is required.

WARNING

Dispose of used battery promptly.
Keep away from children. Do not disassemble and do not dispose of in fire.

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Maintenance
Replacement Procedures

Replacing I/O modules

If any I/O modules need to be replaced, follow the steps in the table below.

Step Action

1 Remove power from controller.
2
3

Remove front cover by loosening the two screws at the top of the enclosure.
Locate the I/O module you want to replace. See figure. Remove terminal board from front of

module by pressing the two locks at top and bottom of the terminal block and pulling the block
straight out. See Figure 37.

9 10 11 12 13 14 15 16

I/O Module Slots

1 2 3 4 5 6 7 8

4

Unplug I/O module PWA from controller slot by pulling the PWA straight out from its slot.

CPU

Power
Supply

5

Carefully insert the replacement I/O module PWA into controller slot making sure the PWA is
properly aligned in the guides.

6
7
8
9

Plug in the terminal block to the I/O module PWA so it is securely attached.
Install front cover. Secure with two screws.
Restore power to controller.
Verify calibration of I/O module (AI or AO modules). Perform calibration of AI modules and

CJC references (if using T/C) for all channels if greater than 0.1% accuracy is required.

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I/O Module
Identification

12
11
10

Maintenance

Replacement Procedures

Locks

2

9
8
7
6
5
4

3
2
1

Field Wiring
Terminals

Locks

Figure 37 I/O module terminal blocks (not shown: 16 point DI)

Replacing the CPU module

Follow the steps in the table below for replacement of the CPU module in the controller. Please note that
field calibration values for AI modules and CJC references are stored on the CPU. These values must be
restored, if necessary, after a CPU is replaced. [See Controller Calibration (page 65).]

Step Action

1
2
3
4
5
6
7
8
9

Remove power from controller.
Remove front cover by loosening the two screws at the top of the enclosure.
Remove three screws securing the CPU module to the power supply.
Unplug CPU module from controller slot by pulling the PWA straight out from its slot.
Observing the correct polari ty, install battery into the battery holder on the replacement CPU.
Carefully insert CPU module into the enclosure slot and secure with three screws.
Replace front cover and secure with two screws.
Restore power to controller.
Place controller in PROGRAM mode and download controller configuration file.
NOTE: Controller configuration is stored in the battery backed RAM and also in the flash

PROM memory. Since the CPU has been replaced, you must download a valid controller
configuration file to the controller.

10
11

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Verify controller configuration.
Perform calibration of AI modules and CJC references (if using T/C) for all channels if greater

than 0.1 % accuracy is required.

Maintenance
Replacement Procedures

Replacing the power supply module

Step Action

1
2
3
4
5
6
7

8
9

Remove power from controller.

Disconnect power wiring from power supply terminals.
Remove front cover by loosening the two screws at the top of the enclosure.
Remove five screws on the front of power supply securing the CPU module and power supply.
Unplug CPU module from controller slot by pulling it straight out from its slot.
Unplug power supply module from controller by pulling it straight out from its slot.
Plug in the replacement power supply into the enclosure slot and carefully insert CPU module

into its slot.
Secure power supply and CPU with five screws.
Reconnect power wiring to proper terminals on power supply as shown.

F 3,15 AT

250V

Hot

Neutral

Ground

L1
L2 / N

10
11
12

Replace front cover and secure with two screws.
Restore power to controller.
Verify configuration.

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Replacing the backplane

Step Action

Maintenance

Replacement Procedures

1
2
3
4
5
6
7

Remove power from controller.

Disconnect power wiring from power supply terminals.
Remove front cover by loosening the two screws at the top of the enclosure.
Remove five screws on the front of power supply securing the CPU module and power supply.
Unplug CPU module from controller slot by pulling it straight out from its slot.
Unplug power supply module from enclosure by pulling it straight out from its slot.
Remove all terminal blocks from front of modules by pressing the two locks at top and bottom

of each terminal block and pulling the block straight out.

Locks

12
11

I/O Module
Identification

10

2

9
8
7
6
5
4

Field Wiring
Terminals

3
2
1

Locks

8

9
10
11
12
13
14
15
16
17

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Unplug all I/O module PWAs from controller slot by pulling the PWA straight out from its slot.
Be sure to note the slot position of the I/O modules.

Remove two screws (one on each side) at top of enclosure and slide top of enclosure forward.
Remove ten screws securing the backplane to the enclosure.
Lift backplane up though the top of the enclosure.
Carefully install replacement backplane in enclosure and secure with screws.
Slide metal top of enclos ure in place and secure with two screws.
Plug in each I/O module PWA into its proper slot.
Insert all terminal blocks onto the front of each module.
Plug in the power supply into the enclosure slot and carefully insert CPU module into its slot.
Secure power supply and CPU with five screws.

Maintenance
Replacement Procedures

Step Action

18

19
20
21

Reconnect power wiring to proper terminals on power supply as shown.

F 3,15 AT

250V

Hot

Neutral

Ground

L1
L2 / N

Replace front cover and secure with two screws.
Restore power to controller.
Verify configuration.

Perform calibration of AI modules and CJC references (if using T/C) for all channels if greater
than 0.1 % accuracy is required.

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Diagnostics and Troubleshooting

Overview

This section provides diagnostic and troubleshooting information to help in evaluating controller operating
status, diagnosing faul t conditions and taking ac tions to correct faults. An overview of diagnost i c routines
and detail of the indicators used to inform users of controller operating status is provided. Status conditions
are listed, as well as the possible cause and recommended user action for correcting fault conditions, if
necessary.

Controller Diagnostics

Diagnostic routines are executed upon power up of the controller CPU and performed continuously during
controller operation. A number of methods are used to indicate controller status to the operator. LEDs on
the CPU panel provide indication of controller power, operating mode, CPU battery status and diagnostic
status. The operator interface and the user utility program contain displays that show status and operating
parameters in more detail.

Diagnostics and Troublesho otin g

Overview

Power up diagnostics

When power is applied to the controller, a sequence of checks are performed by the controller and
completed in less than 10 seconds after power is applied. These checks are a set of internal diagnostics to
verify the integrity of t he hardware, the configuration database and firmware.

• A hardware check verifies the type of I/O module present in each slot and if the module present is the

correct type for the control strategy in the controller database.

• The controller verifies that a valid configuration database is present in memory.

Communication between the operator interface and controller is established automatically after both
components have completed their restart routines and are ready to begin normal operation.

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Diagnostics and Troublesho otin g
Controller Diagnostics

Controller status LEDs

Status indicators on the controller consist of four LEDs that indicate good and fault conditions in the
controller. These LEDs indicate controller status and help to aid troubleshooting when the operator
interface is not nearby or when the controller is not communicating with the operator interface or PC.
Table 19 describes the LEDs and the possible states with their meaning. Refer also to Table 20 and Table
21 for further details on the meaning of the status LEDs.

Status LED State Meaning

Table 19 Controller status LEDs

POWER

LoBAT

FORCE

RUN

Diagnostic displays

Controller diagnostic summary

Status information, which indicates normal and/or fault conditio ns in the controller as a result of diagnostic
routines, is accessed through either the operator interface or the user utility program.

Steady on Power is applied to the controller backplane.

Blinking Diagnostic indication.

See Table 20 for the details of the indications and their

meaning.
On The CPU battery is low and needs replacement.
On

On Controller is in Run mode.

Blinking Controller is in Offline mode

Off Controller is in Program mode.

One or more function block output values have been

forced.

OR

If POWER LED is blinking a fault has been detected in

controller. See Table 20 for details of the indications and

their meaning.

• Using the operator interface – the DIAGNOSTIC SUMMARY display lists various contro ller

components and their current status.

• Using the user utility program – the Controller Diagnostic Summar y window provides a more extensive

list of controller parameters and communications status.

I/O module diagnostics

Another status display (or window), I/O Module Diagnostics, shows the status of each of the 16 I/O module
slots in the controller. Each module slot is listed along with the status of the module in that slot.

Table 20 gives the details of the messages shown in the Controller Diagnostic Summary and Table 21
describes I/O Module Diagnostics messages that may appear in each field.

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Fault Detection and Troubleclear ing

Interpreting the controller status and determining if any corrective action is necessary can be done by
referring to Table 20 and Table 21. Actions to clear fault conditions usually consist of restarting the
controller, and if the fault reoccurs, replacing the suspected faulty component. It is recommended that you
replace controller components only after performing all other actions listed for that fault condition.

NOTE: The controller status POWER LED is used to indicate a number of faults. A diagnostic fault
causes the POWER LED to flash. The LED will flash a number of times to indicate the type of fault
detected. (See the column “Controller LED on CPU” in Table 20.) The LED flashes quickly a number of
times followed by a long off period. This is similar to a telephone answering machine which uses a
flashing LED to indicate the number of messages. This indication is helpful when the operator interface or
PC is not connected or is not communicating with the controller.

ATTENTION

When replacement of a controller component is neces sary , refer to procedur es in
Maintenance section.

Table 20 Details of the diagnostic summary display

Diagnostics and Troublesho otin g

Fault Detection and Troubleclearing

Controller

Diagnostic Summary

(In the User Utility and Operator

Interface)

Menu

Item

−−

SYSTEM

SYSTEM

SYSTEM

SYSTEM

Status Possible Cause Controller Action User Action

GOOD RUN LED on Controller is in

OFFLINE MODE RUN LED

PROGRAM
MODE

INVALID
CONFIG.

Controller

LED on CPU

POWER
LED flashes
1 time.

flashes.
RUN LED

off.
RUN LED

off.

And

POWER
LED strobes
12 times.

Fault Detection / Troubleclearing

RAM failed on
power-up.

RUN mode.
Controller is in

OFFLINE mode.
Controller is in

PROGRAM mode.
A configuration

with more than 8
loops was
downloaded to an
8 loop controller.

Incomplete
download of
configuration files.

Executes an infinite
loop that toggles
the LED.
Communications
and control are
disabled.

Executes the run
mode.

Executes the
Offline mode.

Function blocks are
not executed.

Empty database
created.

Cycle power;
If fault reappears,

replace CPU.

None

None

None

Download
previous valid
configuration.

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Diagnostics and Troublesho otin g
Fault Detection and Troubleclearing

Controller

Diagnostic Summary

(In the User Utility and Operator

Interface)

Menu

Item

SYSTEM

CPU
CPU

Status Possible Cause Controller Action User Action

TASK FAULT RUN LED

GOOD
WATCHDOG

Controller

LED on CPU

Software failure. Function blocks are

off.

And

POWER
LED flashes
3 times.

−− −

POWER
LED flashes
3 times.

Watchdog reset
resulting from
software failure.

Fault Detection / Troubleclearing

not executed.

Executes normally.

1. Force a cold

start. (Toggle
controller mode
switch from
PGM to RUN.)

2. Upgrade

controller
software.

3. Replace CPU

board.

4. Contact

Honeywell.

none

1. Force a cold

start. (Toggle
controller mode
switch from
PGM to RUN.)

CPU

BUS ERROR POWER

LED flashes
4 times.

Bus Error
Detected.

Executes normally.

2. Upgrade

controller
software.

3. Replace CPU

board.

4. Contact

Honeywell.

1. Force a cold

start. (Toggle
controller mode
switch from
PGM to RUN.)

2. Isolate system

from noise and
force a cold
start.

3. Replace CPU

board.

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Diagnostics and Troublesho otin g

Fault Detection and Troubleclearing

Controller

Diagnostic Summary

(In the User Utility and Operator

Interface)

Menu

Item

CPU

CPU

Status Possible Cause Controller Action User Action

ADDRESS
ERROR

INSTRUCTION
ERROR

Controller

LED on CPU

POWER
LED flashes
4 times.

POWER
LED flashes
4 times.

Address Error
Detected.

Bad Instruction
Detected.

Fault Detection / Troubleclearing

Executes normally.

1. Force a cold

2. Isolate system

3. Replace CPU

Executes normally.

1. Force a cold

2. Isolate system

start. (Toggle
controller mode
switch from
PGM to RUN.)

from noise and
force a cold
start.

board.

start. (Toggle
controller mode
switch from
PGM to RUN.)

from noise and
force a cold
start.

CPU VECTOR

ERROR

POWER
LED flashes
4 times.

Bad Vector
Interrupt.

Executes normally.

3. Replace CPU

board.

1. Force a cold

start. (Toggle
controller mode
switch from
PGM to RUN.)

2. Isolate system

from noise and
force a cold
start.

3. Replace CPU

board.

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Diagnostics and Troublesho otin g
Fault Detection and Troubleclearing

Controller

Diagnostic Summary

(In the User Utility and Operator

Interface)

Menu

Item

CPU

MEMORY GOOD
MEMORY LOW BATTERY Lo BATT

MEMORY FLASH ERROR

Status Possible Cause Controller Action User Action

SPURIOUS
INTERRUPT

Controller

LED on CPU

POWER
LED flashes
4 times.

−− −

LED on.
POWER

LED flashes
5 times.

Fault Detection / Troubleclearing

Spurious Interrupt. Executes normally.

Battery voltage is
low.

Flash PROM failed
to burn.

Executes normally.

Executes normally.

1. Force a cold

start. (Toggle
controller mode
switch from
PGM to RUN.)

2. Isolate system

from noise and
force a cold
start.

3. Replace CPU

board.
none
Replace battery.

1. Force a cold

start. (Toggle

controller mode

switch from

PGM to RUN.)

RTC

(Real
Time
Clock)

RTC

GOOD
NOT

PROGRAMMED

BAD DATA

−− −

POWER
LED flashes
6 times.

POWER
LED flashes
7 times.

RTC not
programmed

Bad time and date.

Time and date is
set to 00:00:00,
January 1, 1970.

Time and date is to
00:00:00, January
1, 1970.

2. If fault

reappears,

replace CPU

board.
none
Enter correct time

and date.

1. Program RTC.

2. Cycle power.

3. Replace CPU.

4. Replace

boards in

backplane.

5. Replace

backplane.

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Diagnostics and Troublesho otin g

Fault Detection and Troubleclearing

Controller

Diagnostic Summary

(In the User Utility and Operator

Interface)

Menu

Item

RTC

RTC

Status Possible Cause Controller Action User Action

BATTERY
FAILURE

PROGRAMMING
FAILURE

Controller

LED on CPU

POWER
LED flashes
8 times

POWER
LED flashes
7 times

Fault Detection / Troubleclearing

RTC battery failed
on power-up

RTC failed to
program

Time and date is
set to 00:00:00,
January 1, 1970.

Time and date is
set to 00:00:00,
January 1, 1970.

1. If Lo BAT LED

is off, cycle

power.

2. If Lo BAT LED

is on, replace

battery and

cycle power.

1. Program RTC.

2. Cycle power.

3. Replace CPU.

4. Replace

boards in

backplane.

5. Replace

backplane.

RTC

I/O
I/O

I/O

I/O

READ FAILURE POWER

LED flashes
7 times

GOOD
MODULE

ERROR

BAD BACKPAN

BAD BACKPAN
ID

−− −

N/A

POWER
LED flashes
9 times.

POWER
LED flashes
9 times.

Unable to read
RTC

One of the I/O
board diagnostics
failed.

Bad backplane
EEPROM

Incompatible
backplane board

Time and date is
set to 00:00:00,
January 1, 1970.

N/A

Analog inputs use
default coefficients.

Analog inputs use
default coefficients.

1. Program RTC.

2. Cycle power.

3. Replace CPU.

4. Replace

boards in

backplane.

5. Replace

backplane.
none
Access the I/O

MODULE
DIAGNOSTICS
display.

1. Cycle power.

2. Replace

backplane

board.

1. Cycle power.

2. Replace

backplane

board.

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Diagnostics and Troublesho otin g
Fault Detection and Troubleclearing

Controller

Diagnostic Summary

(In the User Utility and Operator

Interface)

Menu

Status Possible Cause Controller Action User Action

Item
COMM A
COMM A

GOOD
BOARD

FAILURE

COMM A

BOARD NOT
FOUND

COMM B
COMM B

GOOD
BOARD

FAILURE

Controller

Fault Detection / Troubleclearing

LED on CPU

−− −

POWER
LED flashes
13 times.

POWER
LED flashes
13 times

The COMM A port
hardware has a
serious failure.

The main CPU
board has a non­default address

Executes normally. Replace Comm

Executes normally.

and no COMM
port installed.

−− −

POWER
LED flashes
13 times.

The COMM B port
hardware has a
serious failure.

Executes normally.
All Modbus read
block outputs are
frozen at their last
read values.

none

board.

Install CPU with
optional RS 485
communications
(if not installed)
or set COMM A
station address to

255.
none
Replace CPU.

COMM B

PANEL
(OI)

BOARD NOT
FOUND

NORMAL

POWER
LED flashes
13 times

The control file
configuration
requires a master
port and no Comm
Port is installed.

Executes normally.
All Modbus read
block outputs are
frozen at their last
read values.

−− −

Install Comm
Board or
download a
configuration that
has no Modbus
slave blocks

none

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Fault detection and troubleclearing

Table 21 describes the status messages that appear on the I/O Module Diagnostics displays in the user
utility and operator interface, as well as the status indications of the POWER LED located on the controller
CPU module.

Table 21 Details of the I/O module diagnostics display

Diagnostics and Troublesho otin g

Fault Detection and Troubleclearing

I/O Module

Diagnostics

(In The User Utility and

Operator Interface)

Menu

Item
MODULE

1 through
MODULE
16

MODULE
1 through
MODULE
16

MODULE
1 through
MODULE
16

GOOD

HI CJ
TEMPERATURE

WRONG
MODULE

Controller

LED on CPU

Status Possible Cause Controller Action User Action

−− − −

POWER
LED flashes
10 times

High cold junction
temperature on AI
module.

Fault Detection / Troubleclearing

Executes normally.

1. Improve

ventilation to
rack.

2. Replace AI

module

POWER
LED flashes
11 times

The module does
not agree with the
module required
for the control
strategy.

These function
block types do the
following:

AI – sets its output
to failsafe

DI – sets its output
to OFF

1. Replace

module.

2. Check

configuration.

MODULE
1 through
MODULE
16

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NO MODULE POWER

LED flashes
11 times.

No module found
in the slot that
requires a module
for the control
strategy.

These function
block types do the
following:

AI – sets its output
to failsafe

DI – sets its output
to OFF

1. Install the

correct type of
module.

2. Check

configuration.

Diagnostics and Troublesho otin g
Fault Detection and Troubleclearing

I/O Module

Diagnostics

(In The User Utility and

Operator Interface)

Menu

Item
MODULE

1 through
MODULE
16

BAD MODULE POWER

Controller

LED on CPU

Status Possible Cause Controller Action User Action

Analog input or
LED flashes
11 times.

analog output

board does not

have factory

coefficients, or the

I/O board is not a

supported type.

Fault Detection / Troubleclearing

1. If the error is an

analog input
board with no
factory
coefficients,
default
coefficients will
be used for the
cold-junction
calculations.

Replace module.

2. If the error is an

analog output
board with no
factory
coefficients,
default
coefficients will
be used for the
outputs.

3. If the board is an

unsupported
type, these block
types do the
following:

AI – sets its
output to failsafe

DI – sets its
output to OFF

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Modem troubleshooting

Controller modem problems will typically show one of two symptoms.

• The modem does not answer, or

• the modem answers but does not establish communications.

Modem not powered. Apply power.
Modem not configured for auto answer. Check modem configuration and correct.
Modem not properly connected to phone line. Verify phone line is correctly inserted in modem

Bad cable connecting modem to phone line. Replace cable with known good cable.

Diagnostics and Troublesho otin g

Fault Detection and Troubleclearing

Table 22 Controller modem troubleshooting

Modem does not answer

Cause Solution

port and wall jack.

Modem answers but does not establish communications

Cause Solution

Controller not powered. Apply power.
Modem set to wrong baud rate. Follow procedure to set modem to 9600 baud.
Modem configuration does not match specification. Follow procedure to configure modem. See

Remote Access (page 44).

Modem does not have non volatile memory. Replace modem with one of the recommended

types. See Remote Access (page 44).
Bad cable between modem and controller. Replace with a known good cable.
Wrong cable between modem and controller.

Replace with correct cable (not a null modem

cable).
Controller failure. Contact Honeywell service.

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Diagnostics and Troublesho otin g
Fault Detection and Troubleclearing

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UMC800 Controller

If you require replacement or spare parts for the UMC controller, you can order them by referring to the
table below and contacting your Honeywell representative.

Replacement parts

Analog Input Card 46190305-503
Analog Output Card 46190314-503
DO Relay Output Card 46190308-503
DO AC Output 46190344-501
DO AC Output (2 @ 2 A and 4 @ 0.5 A) 46190344-502
DO DC Output 46190341-501
DI Contact Input (6) 46190311-503
DI Contact Input (16) 46190353-501
DI AC Input 46190350-501
DI DC Input 46190347-501
Pulse/Frequency Input Card 46190360-501
± 15 Vdc pH Power Module 51450921-501
Controller Terminal Board Cover 51309474-501
RS 485 Comm Card Kit (for controllers purchased 3-99 to 2-00) 51404868-501
RS 485 Comm Card Kit (for controllers purchased after 2-00) 51404868-502
Ethernet Communications Card Upgrade Kit (for controllers purchased

after 12-00)
Power Supply
100-240 V ac or dc

24 V ac or dc (Optional)
Controller CPU Kits (for controllers purchased 3-99 to 2-00):

Up to 8 PID Loops
Up to 16 PID Loops
Up to 8 PID Loops with RS 485 Communications
Up to 16 PID Loops with RS 485 Communications

Controller CPU Kits (for controllers purchased after 2-00):

Up to 8 PID Loops
Up to 16 PID Loops
Up to 8 PID Loops with RS 485 Communications
Up to 16 PID Loops with RS 485 Communications

Battery (for CPU) 51198364-501

Parts List

UMC800 Controller

Parts List

Part Description Part Number

51500651-501

46190250-502
46190250-504

51404865-501
51404865-502
51404865-503
51404865-504

51404865-505
51404865-506
51404865-507
51404865-508

Backplane Assembly 46190329-502
I/O Black Terminal Block 46190202-501

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Parts List
UMC800 Controller

I/O Red Terminal Block 46190204-501
Controller Fuse for 100-240 V supply (1 each) 46182886-002
Controller Fuse for 24 V supply (1 each)
Grommet Kit (Power Terminal Cover, Grommets (16) 51404796-501
Shield Termination* 51309814-501
Ferrite Suppressor* 51404883-501
250 Ohm Shunt Resistor Kit (for mA ranges) (4) 46181080-503

Part Description Part Number

Null Modem 9-pin “D” connector**

51404755-501

(Cable for connecting Controller to PC)
Cable for connecting Controller to Operator Interface

10 ft cable
50 ft cable

51404523-501
51404523-502

*Shielded analog connections and a ferrite filter on the operator interface cable are required for
CE approval.

**Required for connection from configuration PC to controller.

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