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Conversion Instructions
VAWI1007 Rev. D
September 2018
TEC2000 to TEC2 (Model 500 Discontinued)
Conversion Instructions
I
Conversion Instructions
VAWI1007 Rev. D
Table of Contents
September 2018
Table of Contents
Table of Contents
Section 1: Reference Material
1.1 Work instruction hardware upgrade from TEC2000 to TEC2 .......................... 1
1.2 Work instruction TEC2000 to TEC2 motor heater with transformer conversion
instructions ................................................................................................. 12
1.3 Work instruction TEC2000 to TEC2 ARM (auxiliary relay module)
cover assembly ............................................................................................ 15
1.4 Work instruction TEC2 space heater assembly ............................................. 20
1.5 Work instruction TEC2 and TEC2000 MCM conversion ................................ 25
1.6 Work instruction TEC2000 Futronics ACM (analog input/output) to TEC2 ACM
(analog input/output) conversion ............................................................... 28
1.7 Work instruction TEC2000 to TEC2 capacitor install .................................... 31
1.8 Work instruction TEC2000 to TEC2 overload relay conversion ..................... 34
1.9 Work instruction TEC2 and TEC2000 CAM conversion ................................. 36
1.10 Work instruction DBM conversion TEC2000 to TEC2 ................................... 42
1.11 Work instruction RDM conversion TEC2000 to TEC2 ................................... 46
1.12 Work Instruction TEC2000 to TEC2 MCM interface module ......................... 49
Section 2: TEC2 configuration file convert from
TEC2000 using DCMlink
TM
2.1 Export TEC2000 conguration (Method: TEClink) ........................................ 58
2.2 Export TEC2000 conguration (Method: DCMlink
TM
) ................................... 60
2.3 Import conguration to TEC2 unit (Method: DCMlink
TM
) ............................. 66
2.4 Import conguration to TEC2 unit (Method: DCMlink
TM
rev 2.0) .................. 72
Section 3: TEC2 Electrical Actuator Test Plan
3.1 Test item ..................................................................................................... 74
3.2 Test equipment requirement ....................................................................... 74
3.3 Testing coverage ......................................................................................... 74
3.4 Test Flow .................................................................................................... 76
Section 4: TEC2 Electric Actuator Test Procedure
4.1 Insulation resistance and dielectric test ....................................................... 79
4.2 Pre-conguration ........................................................................................ 79
4.3 Local test / Discrete output test ................................................................... 80
4.4 Remote test / Discrete input test ................................................................. 81
4.5 TEC2 Electrical Actuator Testing Checklist ................................................... 85
Section 5: Reference pictures
Conversion Instructions
VAWI1007 Rev. D
September 2018
1
Section 1: Reference Materials
Reference Materials
Section 1: Reference Material
1.1 Work instruction hardware upgrade from
TEC2000 to TEC2
ASMBL-WI 1007 Date: 12/06/2016
Step Task Image Device Comment
Reference Material
1. TEC2 Conversion Kit Drawings 87293-(_) before beginning disassembly.
2. How to upgrade TEC2000 to TEC2
https://www.youtube.com/watch?v=noqB4miQqMM
3. How to calibrate the TSM
https://www.youtube.com/watch?v=JULXnqS-Ous
1
Before disassembly
starts, save a copy of the
conguration le using
DCMlink
TM
software.
TEC2000 Unit
This document is for
reference only.
Illustrations may not
mirror your current
situation.
2
Gather the required TEC2
upgrade kit.
Basic TEC2
Upgrade Kit
Note:
LDM faceplate can be
either EIM or Bettis.
Refer to
TEC2 Conversion
Kit Drawing A-H
for Upgrade kit
availability.
3 Gather needed tools. Needed tools
13mm adjustable
extension sockets
and wrench
at head
screwdriver
small torx head
screwdriver
1/4" nut driver
wire cutters
O-ring tool
and needle nose
pliers
4
Lay the unit onto its side.
Using a 1/2" socket,
remove all (16) bolts from
all (4) cover assemblies.
ACM
MCM
STC
LDM
1/2" Socket
Follow standard
safety procedures
during operation
5
To remove the cover
assemblies, a at head
screw driver or a prying tool
can be used to separate the
cover(s) from the housing.
Do not scratch the
machined surface.
This is a ame path.
Conversion Instructions
VAWI1007 Rev. D
September 2018
2
Section 1: Reference Materials
Reference Materials
6
Separate the ribbon
cable to detach the LDM
assembly from the CCM
adaptor.
CCM
LDM
O-Ring
VA4045216317 =
O-ring
Inspect O-rings on
ALL covers after
removal and before
re-install. Replace if
damaged.
Damaged O-rings
could shorten life
time of electronics
devices.
7
Remove the ACM cover
and disconnect all cable
assemblies.
Note:
There could also be
a blank cover in this
location.
Removal is still
required.
8
If user has Controlinc
ACM board with CAM
card or ARM or Futronic
ACM, remove STC cable
connection from CAM and
ACM and reserve the CAM
connection cable.
Photo:
TEC2000
DBM assembly
Note:
TEC2000 Units
with Futronic ACM,
Controlic ACM, DBM,
ARM assembly are
NOT compatible with
TEC2 upgrade kits.
Please consult with
Emerson team for
TEC2 ACM, DBM and
ARM kits.
9
Remove the MCM cover
assembly.
Verify the unit has regular
MCM or hight current MCM.
Photo:
Basic
MCM
# VA84832
Please refer to
section MIM cable
assembly instruction
"ASMBL-WI
10.2.21.1"
Photo:
High Current
MCM
# VA84822
Please refer to
section MIM cable
assembly instruction
"ASMBL-WI
10.2.21.1"
10
Label all wire connections
to the contactor.
Contactor
Wires will need to be
returned to the same
location.
Conversion Instructions
VAWI1007 Rev. D
September 2018
3
Section 1: Reference Materials
Reference Materials
11
Remove all of the wires
from the MCM assembly by
loosening Screws.
Flat head
screwdriver
12
Remove the STC assembly.
Remove all cables from the
STC PC board by pulling
gently on the connectors.
13
Remove the IOM from the
STC by rocking and pulling
the Board from side to side
until freed.
O-Ring
Inspect O-ring
Note:
If user has TEC2000
DBM module -
Remove the pin cable
connection from
the STC to DBM and
dispose the cable,
please consult with
Emerson team for
TEC2 DBM module.
14
From here, start to remove
the hardware from inside of
the TEC2000.
15
Start by removing the CCM
assembly from the unit.
CCM
16
To remove the CCM,
loosen the (1) screw on the
mounting plate with a small
Philips head screwdriver.
Phillips head
screwdriver
Please refer to
section 1.4 space
heater instruction,
if the unit's
conguration require
space heater for TEC2
unit.
17
Then detach the ribbon
cable connection from the
CCM to the APD.
CCM
APD
Conversion Instructions
VAWI1007 Rev. D
September 2018
4
Section 1: Reference Materials
Reference Materials
18
Remove and discard the
CCM assembly from the
unit.
19
Loosen screw to remove the
APD from the plate.
Flat head
screwdriver
An electrician's
screwdriver with
an insulated handle
which protects the
electrician from
shock.
20
Remove the APD drive gear
and torque limit.
APD drive
Torque limit
Flat head
screwdriver
21
To remove the APD plate,
remove the (2) snap rings.
Snap ring tool
Note:
These snap rings
can be used later
as long as removed
undamaged.
22
Now you can remove the
APD plate.
23
Now the CCM mounting
bracket can be removed.
24
Remove the (3) bolts from
CCM mounting bracket
with
5/16 Allen wrench.
5/16 Allen
wrench
25
Remove the mounting
bracket from the unit.
26
Using a 9/16" socket,
ensure the (4) bolts inside
of the housing are secured
tightly.
Conversion Instructions
VAWI1007 Rev. D
September 2018
5
Section 1: Reference Materials
Reference Materials
27
When disassembly is
completed the CCM/MCM
Adapter, IO<, LDM, STC.
MCM. ACM or blank cover,
APD assembly, APD drive,
mounting plate, bracket,
TQ arm assembly, and ALL
ribbon cable should be
removed.
28
Begin to install TEC2
hardware.
29
Installation of the APD
extension plate can begin.
VA38449-2 =
APD extension
plate
Note:
The APD assembly
will be
secured with (4)
preinstalled screws
to the plate in these
locations.
30
Press the mounting plate
over the gear and torque
limits.
The hole pattern should be
located around the gear
limit.
Note:
Insure the thicker
side of the mount
plate is at the top.
As shown.
31
To hold the mounting plate
in place, install the (2) RTN
rings onto the gear and
torque limits.
(2)
VA4060091112 =
retaining ring
Note:
RTN rings should be
installed with the
beveled side up, to
ensure the plate
stays tight.
32
Refer to assembly drawing
for required APD driver.
48T
30T
VA37023-2C =
48T APD Gear
Magnet
or
VA37024-2C =
30T ADP Gear
Magnet
33
Install the new APD drive
gear with screwdriver.
Flat head
screwdriver
34
Apply a drop of red loctite
to the threads of the torque
magnet.
LocTite 263
35
Insert the magnet into the
T2 limit driver by twisting
into place.
VA87107 =
TEC1A Magnet
assembly
Refer to
ASMBL-WI 10.3.11
for magnet assembly
Conversion Instructions
VAWI1007 Rev. D
September 2018
6
Section 1: Reference Materials
Reference Materials
36
Refer to assembly drawing
for required APD assembly.
Refer to
ASMBL-WI 10.30.1
ASMBL-WI 10.30.2
ASMBL-WI 10.30.3
for complete APD
assembly.
37
To identify the correct APD
assembly.
Turn the assembly over to
view the rst stage gear.
VA38229-12 =
12T gage
1:4
VA38229-30 =
30T gage
1:1
38
Install the new APD.
Secure with the (4)
preinstalled screws to the
mounting plate.
Locations identied on
Step 29.
39
Install the (3) standoffs into
the APD plate by hand.
Tighten with small
adjustable wrench.
(3)
VA4046000070 =
6-32 Hex
Standoff .50
(M/F)
Adjustable
wrench
40
Install the (TSM) Torque
Switch Module plate with
(3) screws using a small
Torx head screwdriver.
VA38450 =
HTPS mount
plate
(6) VA36584 =
Torx ES Pan
6-32 x .31
41
Install the TSM board, and
support onto the TSM plate
with the last (3) screws.
(Do Not Tighten)
VA87200 = (TSM)
Torque Switch
Module, M-500
VA38150 =
TSM Support
42
TSM calibration must be
done at this point.
Refer to
YouTube video
for calibration
instructions.
Conversion Instructions
VAWI1007 Rev. D
September 2018
7
Section 1: Reference Materials
Reference Materials
43
Retrieve the calibration
tool.
TQ Sensor
Stimulator Tool =
VA87354-DD
Note:
TSM Calibration:
A TQ Sensor is
connected to the
TSM to locate the
proper position of
the TSM.
44
Step 1
Connect the end of the
TQ Sensor to the (P1)
connector on the TSM.
Note:
Calibration tool red
light will remain
on until TSM is
in the calibrated
position. Once TSM
is calibrated the light
will turn green.
45
Step 2
Rotate the TSM until the
Red LED light turns green.
Once the LED turns green,
tighten the (3) screws.
LED
Small Torx head
screwdriver.
46
Install the blue cable onto
(P1) of the TMS and (P1) of
the APD assembly.
TSM
APD
VA87207-4 =
APD/TSM Cable
All wires and
harnesses are to be
checked with a slight
pull, to ensure proper
connections.
47
Move to the STC assembly.
Push down rmly to insert
the IOM Board into the STC.
IOM Board
VA84949 =
IOM Board.
Do not use more
force than necessary.
48
Run the STC wires through
the main housing to the
MCM assembly.
IOM Ground
Note:
Please refer to
section MIM cable
assembly instruction
"ASMBL-WI
10.2.21.1" for MCM
to CCM connection.
49
MCM wiring can now begin.
Connect the ground wire to
(P2) on the MCM board.
MCM Ground
Conversion Instructions
VAWI1007 Rev. D
September 2018
8
Section 1: Reference Materials
Reference Materials
50
Insert Molex connector to
(2) MCM locations.
Per wire diagram,
connect voltage wires into
(P20) location on the MCM.
HSG4
HSG6
VA7030020027 =
Recpt HSG4 CKT
Single Row (P19)
VA7030020026 =
Recpt HSG6 CKT
Double Row (P20)
51
Secure the (3) numbered
black motor wires to
contactor by tightening
screws.
Phillips head
screw driver
Light pull to insure
proper connection
and contactor screws
are tightened.
52
Pull remaining STC wires
through the main housing.
53
Identify the numbered
wires.
54
Per wire diagram, insert
all (4) required wires into
Molex connector (P19).
VA7030020027 =
Recpt HSG4 CKT
Single Row
55
Per wire diagram, connect
all remaining wires to the
contactor.
Phillips head
Screwdriver
56
Per wire diagram, once
complete, check all
connections to the
contactor and MCM
assembly.
Insure all wires and
screws are fastened
securely whether
used or not.
Conversion Instructions
VAWI1007 Rev. D
September 2018
9
Section 1: Reference Materials
Reference Materials
57
Use cable ties to unify all
cables and wires to the
MCM.
Cable Ties
As shown.
58
Reach into the unit to
tie all interior wires and
harnesses.
59
Clip the excess cable tie
ends.
Wire clipper
60
Use a air hose to clean
all debris from interior of
housing.
Air hose
Follow standard
safety
procedures during
operation.
61
Lay out remaining harness
assemblies and covers.
Refer to
TEC2 conversion kit
drawing A-H.
62
Final assembly of the STC
can now begin.
Please refer to
section MIM cable
assembly instruction
"ASMBL-WI
10.2.21.1" for MCM
to CCM connection.
63
Connect all wires and
harnesses to the STC.
Note:
Cables can only be
connected where
they are supposed to
go in, they can not be
confused or t into
other locations.
Conversion Instructions
VAWI1007 Rev. D
September 2018
10
Section 1: Reference Materials
Reference Materials
64
Ensure the IOM is seated
properly into the STC by
pushing down rmly to
ensure connection.
Do not apply more
pressure than
necessary.
65
Run the remaining
harnesses from the STC
through the main housing.
As shown.
66
Use paint brush to apply
grease on all cover anges
before placing onto the
unit.
Dielectric Grease
Small Paint Brush
67
Place MCM cover assembly
into unit.
Careful not to pinch
any wires.
68
Use paint brush to apply
grease on the STC cover
ange.
69 Use mallet to secure covers.
Tap lightly -
Scratches will VOID
certication.
70
Rotate the STC cover onto
the STC until secured.
Conversion Instructions
VAWI1007 Rev. D
September 2018
11
Section 1: Reference Materials
Reference Materials
71
Carefully pull the remaining
harnesses through to the
LDM side of the unit.
72
Secure all remain harnesses
to the LDM.
VA87086-1 =
APD/CCM Cable
P9 to P9
VA870087-1 =
IOM/CCM Cable
P3 to P3
VA87087-2 =
MCM/CCM Cable
P5 To P5
Note:
Cables can only be
connected where
they are supposed to
go in, they cannot be
confused or t into
other locations.
Photo shows an LDM
with optional CAM
and ACM boards.
73
Secure the LDM cover to
the unit.
MCM/CCM
MCM/CCM
APD/TSM
APD/CCM
Inside View
74
Using a 1/2"" socket,
replace all (16) bolts
to secure all (4) cover
assemblies.
1/2" socket
Before disassembly
starts, save a copy
of the conguration
le using DCMlink
TM
software.
75
TEC2000 conversion to
TEC2 is complete and ready
for testing.
Upload copy of the
conguration le using
DCMlink
TM
software.
Note:
Before unit is
ready for testing
the conguration
le saved in the
beginning must be
installed.
Conversion Instructions
VAWI1007 Rev. D
September 2018
12
Section 1: Reference Materials
Reference Materials
Revision Work Instructions
ASMBL-WI 10.2.20 TEC2000 to TEC2 MCM CONVERSION
ASMBL-WI 10.6.28 TEC200 to TEC2 RDM CONVERSION
ASMBL-WI 16.26.1 TEC2 SPACE HEATER/BRACKET ASSEMBLY Rev1
ASMBL-WI 16.30 TEC2000 Futronics ACM (Analog input-output) to TEC2 (Analog input-output) CONVERSION
ASMBL-WI 16.31 TEC2 ARM ASSEMBLY
ASMBL-WI 16.32 TEC2000 to TEC2 DBM CONVERSION
ASMBL-WI 16.33 TEC2000 toTEC2 TRANSFORMER CONVERSION
ASMBL-WI 16.34 TEC2000 to TEC2 OVERLOAD RELAY INSTALL
ASMBL-WI 16.35 TEC2000 to TEC2 CAM CONVERSION
ASMBL-WI 16.36 TEC2000 to TEC2 CAPACITOR INSTALL
ASMBL-WI 10.2.21.1 TEC2000 to TEC2 MIM (TEC MCM INTERFACE MODULE) CABLE Assembly
Revision History
Rev No. Date Description By: Approved:
0 3/1/2017 Initial Release W. Jones K. Wood
1 3/24/2017
Added Upgrade Kit, O-ring
and MCM information,
updated part #'s.
W. Jones
K. Wood
K. Liu
2 5/23/2017
Added Work Instruction
references
W. Jones
K. Wood
K. Liu
3 11/16/2017
Added Work Instruction
references
K. Liu K. Liu
1.2 Work instruction TEC2000 to TEC2 motor heater
with transformer conversion instructions
ASMBL-WI 16.33 Date: 4/28/2017
Step Task Image Device Comment
The instruction is to show the procedure how to relocate the transformer from L-bracket to blank
cover location. The motor heater does not require to perform any change.
The conversion does not require any new part but transformer will be relocated to blank cover
location. Refer to BOM and schematic to assembly instructions.
TEC2000
Transformer
Mounting
TEC2 motor heater
transformer is
compatible to
TEC2000 motor
heater transformer.
1
To start this assembly,
make sure the covers part
number is in the down
position.
VA36838-2B =
BCA (blank
cover)
Conversion Instructions
VAWI1007 Rev. D
September 2018
13
Section 1: Reference Materials
Reference Materials
As shown.
2
Pull the required Loctite for
this application.
Loctite
reliably locks and
seals metal fasteners
up to 1 in. Be quick
with your application
of hardware.
3
Identify the correct side of
the plate.
Locate pre drilled holes
as shown.
Correct
VA37045 =
MCM/ACM
Mount Plate
4
Place a single drop of
red Loctite into the (6)
required locations.
Loctite 263
As shown.
5
Place the mounting plate
into the cover.
6
Line up the largest holes
on the plate with the holes
with the Loctite drops.
Conversion Instructions
VAWI1007 Rev. D
September 2018
14
Section 1: Reference Materials
Reference Materials
7
Use a hex driver to secure
the plate into the cover by
placing (6) Torn Bux screws
in the same (6) larger holes
with the Loctite drops.
(6)
VA36256 =
TORX BUX
8-32 X .31
8
Retrieve the required
Transformer module.
Place into the center of the
plate
Hi, H2 for L1,
L2 from STC
X3, X4 for
110V output
9
(1) maybe (2) of the hole
will line up with the plate.
(2) or more holes will need
to be drilled into the plate
to secure the transformer
into place.
10
Once the transformer has
been secured to the plate.
Per wire diagram
instructions, connect the
required wires to there
prospective locations.
11
Secure the transformer
cover assembly onto the
housing.
Inside view of the
transformer.
Revision History
Rev No. Date Description By: Approved:
0 5/4/2017 Initial Release W. Jones K. Liu
Conversion Instructions
VAWI1007 Rev. D
September 2018
15
Section 1: Reference Materials
Reference Materials
1.3 Work instruction TEC2000 to TEC2 ARM
(auxiliary relay module) cover assembly
ASMBL-WI 16.31 Date: 4/23/2017
Step Task Image Device Comment
SCOPE:
This document briey explains with pictures how to assemble ARM cover assembly.
(Two Options)
Option 1: LDM (87192) + CCM (VA87191) + ARM (VA87190)
Option 2: LDM (87192) + CCM (VA87191) + ACM(VA87139) + ARM (VA87190)
Refer to BOM and schematic to assembly instructions.
VA84649 =Old
TEC2000 ARM
assembly
Option 1
ARM without ACM
LDM (87192) + CCM (VA87191) + ARM (VA87190)
1
Gather all required
hardware and PCB's for this
assembly
If user already have
LDM sub-assembly,
jump to step
11(87307-1 ARM
KIT,TEC2)
2
Retrieve LDM cover
assembly
VA36935-5
=LDM Cover
Assembly
3 Retrieve LDM assembly
VA87192 =TEC
LDM Assembly
4
Place the LDM into the
cover assembly the LDM
screen down into the glass.
Conversion Instructions
VAWI1007 Rev. D
September 2018
16
Section 1: Reference Materials
Reference Materials
5
J11 connector should be as
shown.
6
Retrieve the required
amount of standoffs for
assembly.
Option 1 =
Qty. 16
Option 2 =
Qty. 16
VA4046000071
=
6-32 HEX
STANDOFF .50
(M/F) SS
7
Use the 1/4"Hex driver
position.
As shown.
8
Retrieve TEC CCM PCA
(VA87191) for assembly.
Insert (2) standoffs into
the top of the CCM board.
Secure with (2) nuts on the
bottom of the board.
Top view of CCM
(2)
VA4046000071
=
6-32 HEX
STANDOFF .50
(M/F) SS
As shown.
Bottom view of
CCM
(2)
VA4042900102
=
NUT 6-32 UNC
SS
9
Insert the screw through
the top of the board,
secure the standoff onto
the bottom of the board.
As shown.
To view of CCM
(4)
VA4046000071
=
6-32 HEX
STANDOFF .50
(M/F) SS
Conversion Instructions
VAWI1007 Rev. D
September 2018
17
Section 1: Reference Materials
Reference Materials
As shown.
Bottom view of
CCM
(4)
VA4042650001
=
FLMS
6-32 X .25 SS
10
Line up the LDM connecter
J11 with CCM connector
J11.
MCM
LDM
Ensure the
connectors are lined
properly.
Easy to damage.
11
Push down gently to
connect the (2) PCBs
together.
Locate the P19 connector
on the TEC ACM PCB.
If user already have
LDM sub-assembly,
user could start from
step 11 to insall ARM.
12 Retrieve TEC ARM PCB.
VA87190 =
TEC ARM
13
Line up the J19 connector
of the TEC ARM with J19
connector of the CCM.
Ensure the
connectors are lined
properly.
14
Push down gently to
connect the (2) PCBs
together.
15
Use a Hex Driver to secure
(5) more standoffs into the
(5) shown locations.
(5)
VA4046000071
=6-32 HEX
STANDOFF .50
(M/F) SS
Option 1
ARM without ACM
/
