Bettis TEC2000 to TEC2 Conversion Operating instructions

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

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 conguration (Method: TEClink) ........................................ 58

2.2 Export TEC2000 conguration (Method: DCMlink

TM

) ................................... 60

2.3 Import conguration to TEC2 unit (Method: DCMlink

TM

) ............................. 66

2.4 Import conguration 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-conguration ........................................................................................ 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

conguration 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

conguration 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 identied 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

certication.

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

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 conguration

le using DCMlink

TM

software.

75

TEC2000 conversion to

TEC2 is complete and ready

for testing.

Upload copy of the

conguration le using

DCMlink

TM

software.

Note:

Before unit is

ready for testing

the conguration

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 briey 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

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Bettis TEC2000 to TEC2 Conversion Operating instructions

Bettis TEC2000 to TEC2 Conversion Operating instructions

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