Convert Working Instructions
TEC2 Electrical Actuator Test Plan
(Model 500 Discontinued)
ACT-MAN-01-04-EN Rev. B
September 2018
Convert Working Instructions
ACT-MAN-01-04-EN Rev. B
Table of Contents
Section 1: TEC2 Electrical Actuator Test Plan
1.1 Test item ....................................................................................................... 1
1.2 Test equipment requirement .........................................................................1
1.3 Testing coverage ........................................................................................... 1
1.4 Test Flow ...................................................................................................... 3
Section 2: TEC2 Electrical Actuator Test Procedure
2.1 Insulation resistance; Día-electrical test ........................................................ 6
2.2 Pre-conguration .......................................................................................... 6
2.3 Local test / Discrete output test ..................................................................... 7
2.4 Remote test / Discrete input test ................................................................... 8
2.5 TEC2 Electrical Actuator Testing Checklist ................................................... 11
Table of Contents
September 2018
Section 3: Reference pictures
Table of Contents
I
Section 1: TEC2 Electrical Actuator Test Plan
September 2018
Convert Working Instructions
ACT-MAN-01-04-EN Rev. B
Section 1: TEC2 Electrical Actuator Test Plan
(Model 500 Discontinued)
This document is made for production and LBP to perform functional verication of TEC2
electronics devices in TEC2 electrical actuator. The goal is to provide detail description
and procedure on how to interact with TEC2 electronics through DCMlinkTM. Through the
manual test process, the tester will require to ll up the form “TEC2 Electrical Actuator
Manual Test Check list” and generate the nal conguration le at the end of test.
Also, tester need send the copy of form and conguration le to Emerson Automation
solution as archive le for future reference.
1.1 Test item
TEC2 unit with conguration (CCM/LDM/ACM/CAM205)/(MCM/APD/TSM/TBM/SSR)
1.2 Test equipment requirement
Multi-meter, jumper, jumper switch, DCMlinkTM rev 1.2, current loop calibrator x2(FLUKE
709), RS485 adapter x2, computer, thermal detector, RPM reader or timer, RDM module,
AC High-Pot tester (230415- BIDDLE)
1.3 Testing coverage
1) Conguration setup and verication. (unit vs spec sheet)
A) Under requirement DCMlinkTM is V1.2 or greater.
B) TEC2 / MODEL 500 (Model 500 Discontinued)
C) Right / Left hand worm
D) Close clock wise / close counter clock wise
E) Reverse rotation
F) Control mode
G) RDM (SW5/SW6)
H) Bluetooth
I) 3-phase/1-phase
J) Starter type
K) Firmware check
L) ACM
M) Unit S/N, motor model
N) Output conguration le to archive
O) LED color setup
1) Where to setup (Factory setting and Detail setup)
2) How to upload and how to export the conguration le
(1.2 rev vs 2.0)
3) Conguration le format. (TEC vs CFG)
4) Others
1
TEC2 Electrical Actuator Test Plan
Convert Working Instructions
ACT-MAN-01-04-EN Rev. B
2) Firmware check
A) Verify the rmware number and date code.
B) CCM: 1.0.4
C) LDM: 1.0.4
3) LDM display check
A) Make sure the color at backlight is even and LED color
B) Make sure the selector knob and control knob able to functional properly
4) APD test
A) Setup travel limit. (at least twice wider than stroke time)
B) Power cycle at 0%, 50%, 100%.
5) LED check
A) Open / close has expecting color output (Red as close or Green as close)
B) Alarm LED
6) RPM test
A) Verify rpm using RPM reader or timer to count turns per min.
7) Rotation rule check
A) Make sure output is in right orientation
B) Make the nal AUX gear box has right orientation
8) Discrete input test
A) Wires control / 3 wires / 2 wires / 3 wires analog
B) Open/Close/ESD inhibit
9) Discrete output test
A) N.C/ N.O in remote
10) Hardware ESD test
A) 20-22 short and failure alarm
11) RDM port test
A) SW5/SW6 and failure alarm
12) Analog input test
A) Analog calibration
13) Analog output test
A) Analog calibration
14) Analog output test
A) Analog calibration
15) DCMlinkTM channel test
A) 115200 x baud rate without encryption setting.
Section 1: TEC2 Electrical Actuator Test Plan
September 2018
1) LDM has individual EEPROM for language selection. If the chip
programmed incorrect, the LDM will show incorrect EEPROM.
1) Fails: Backlight discolor / missing txt / missing line
1) Screw is tightened on knob / no obstacle during knob movement
1) Verify the right hand/ left hand worm, close direction, reverse
rotation
TEC2 Electrical Actuator Test Plan
2
Section 1: TEC2 Electrical Actuator Test Plan
September 2018
16) Network protocol test cam205/cam201
A) 9600 x baud rate
17) Hi-Pot test (AC; 230415)
A) Apply 2.5KV / 1 second on L1,L2,L3 to ground
18) RDM test
A) Precongure RDM and connects to unit to perform remote control
19) Hand-wheel / Power shaft test
A) Enable power shaft to make sure able to operate manually through
handwheel and able to release properly when motor runs.
1.4 Test Flow
Figure 1 (Whole unit high level test flow)
H-JTAG
FW
ICD3
FW
5mins
The unit without ACM/
CAM/ART/RDM/BT/DBM
The unit has one of
ACM/CAM/ART/RDM/
configuration file
server (EMERSON/LBP)
70% Torque in OPEN/
CLOSE with Current
HFS
45mins
BT/DBM/HFS
5-70mins
Save the final
Storage to
clamp reading
10-25mins
CCM
LDM
FIRMWARE
DOWNLOAD
BASIC UNIT
COMPONENT
CONFIGURATION
DYNO TEST
START
ASSEMBLY
PROCESS
HIGH-POT
TEST
TEST
OPTION
TEST
REWORK
OUTPUT
Option: When the
new firmware
released
3 times higher
voltage: 2.5 KV, 6mA,
1 second
YES
If rework happened, the
TEST PROCESS needs to
start from Hipot
END
Convert Working Instructions
ACT-MAN-01-04-EN Rev. B
Tool list:
1. Computer
2. Firmware programmer (H-JTAG for CCM) - option
3. Firmware programmer (ICD3 for LDM) - option
4. RS485 converter x2 (one for 36/38, one for CAM)
5. Analog loop calibrator x2 (one for input control,
one for output feedback)
6. Multimeter (check the relay output)
7. 475 handheld (FF and HART)
8. FF POWER HUB
9. Profitbus modem (BW1257)
(suggest profibus simulator + 5V supply)
10. Devicenet modem (BW1420)
(suggest devicenet simulator + 11-24V supply)
11. Crossover cable (MODBUS TCP/IP)
12. Bluetooth module
13. USB to RS232 (for profibus)
14. Hi-POT tester.
15. Dyno machine.
16. AC current Clamp
17. RPM reader.
Application List
1. TEC2 flasher (CCM/LDM firmware program)
2. DCMLink (36/38 control) (Bluetooth control)
3. Profibus control application
4. Devicenet modem control application
5. Device installer (MODBUS-TCP/IP)
6. MODBUS-POLL (MODBUS-TCP/IP)
Power Requirement
1. 60hz and 50hz frequency
2. 110VAC to 69VAC with 30A each phase
(90% unit coverage)
3. 24VDC with 500W
25mins
CHECK
CORRECT
DYNO CHECK
TORQUE
OUTPUT
70% WITH
AC CURRENT
READING
(OPEN/CLOSE)
CHECK
CORRECT
TORQUE
DIRECTION
3
TEC2 Electrical Actuator Test Plan
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