Emerson Process Management

Valve Actuation LLC

13840 Pike Road
Missouri City, TX 77489
T (281) 499 1561
F (281) 499 8445

TEC 2000 ALARMS

This is a general discussion on Power Fail and Actuator Fail Alarms.
For additional information of other TEC 2000 Alarms see the additional document “TEC 2000
Troubleshooting Guide”.

The Central Control Module (CCM) is the main control board of the TEC 2000 and has a bank
of resistors that serve as the enclosure heater. It receives, regulates, and switches power and
input and output signal communication and circuit switching required for operation and
configuration.
The MCM has the transformer for all module power supplies and the motor control contactor.
The CCM has additional voltage regulation circuits. If you can see the display and are able to
detect 24VDC at Terminals # 9 and #10 of the STM (Separate Terminal Module), then the MCM
Transformer is receiving power. However there are additional taps 24 VAC taps that are feed
directly to the CCM and MCM circuits. There are Electronic Resettable Fuses ("Chiclets") on the
MCM that control some circuits. The actual presence of control power for the control circuits (not
the display) can be detected across terminals # 20 and #22 when the factory jumper is removed
(it should be 24-31VDC)

Power Fail and Power Fail/EFM

Intermittent and recoverable “Power Fail” alarms indicate a connection, configuration, or
operational error (signals to open or close not maintained or changing too rapidly in succession).

“Power Fail” is an Alarm condition whereby the Central Control Module has detected an open
circuit condition that removed control power from the actuator motor directional control circuit
(through Relay K2 on the MCM) that will inhibit operation until the condition is cleared or error
resolved. The directional control interlocking and coil enabling is accomplished through the
switching of relays K3 and K4 of the MCM.
The most frequent cause is a circuit connection issue. If it is missing the jumper 22 to 20 it will
exhibit “Power Fail” without associated "EFM" Alarm. If it has a loose or improperly connected
IOM [Input Output Module which contains relays and is part of the CCM (Central Control Module)
and connects to the STC/STM (Separate Terminal Chamber/Module)] it may also exhibit “Power
Fail” without an "EFM". Occasionally, there could be a hardware failure (MCM Contacts; Control
Relays; or Capacitor Connection or Failure; hardware connection failure: I.E. cold solder joints or
relay contact connection) or a power fail as a result of a low voltage condition. See below for
more details.
 "Power Fail/ EFM" indicates the Electronic Fault Monitor has detected an abnormal condition
or repeated fault condition and enabled a relay (K6 on the CCM) that removes power from the K2
Relay to inhibit further operation. It can be associated with successive repetition of other alarms
noted in the Alarm Log. Failure to pull in the K1 Contactor and K2 Contactor Coils when a signal
is provided will generate a “Power Fail/EFM” alarm. These coils only receive power based on the
contact position of the K3 and K4 relays and the availability of the command input control voltage.
If there is a command and no response to it detected by CCM (through APD updating and Aux
Contact status change) the EFM watchdog timer is set.
If it has had a hardware failure ( MCM, CCM, or APD); or has experienced a "brown out" (dip in
power for control) or multiple “Actuator Fail" alarms; if the Torque Arm that is sensed by the APD
is out of alignment with the APD sensor range (Physically out of position; broken or loose);if the
Torque Arm is in a position for over 10 seconds without an associated indication of a Limit being
made (actuator can have Torque Seated or Torque Back Seat enabled/configured) you could see
the Alarm “Power Fail/EFM”.

Actuator Fail
"Actuator Fail" is a general alarm associated with other alarm conditions or causes and could
mean a number of things associated with operation, commands or configuration. It indicates
a non-recoverable failure requiring maintenance to inspect the equipment to resolve or clear
the condition causing it.
“Actuator Fail” could mean the Motor Thermal or, if applicable, Overload Relay has tripped;
Torque Switch has tripped (Checked Diagnostics Alarm and Torque Profile Data) frequently or
has been driven beyond its Factory Maximum setting or is outside the range of the sensors; the
MCM (Motor Control Module which has Transformer and Reversing Starter and Phase Sentry)
did not respond correctly to the command received (a configuration or wiring error) or has
experienced a hardware circuit failure; APD has failed (actuator can't recognize its limit setting or
detect movement; or the Torque Arm is held out of range of the sensor array); IOM module relay
failure; Jumpers on the STC/STM have come loose and connection lost or open.
Check for Additional Alarms that may direct you to a specific item such as Overload
Relay/Motor or APD.

The error message “Actuator Fail, APD Error (with or without additional error message
“Comfit Error”) is often caused by driving beyond the Factory Max torque setting. It may be
cleared after resolving the issue with the torque condition (move the actuator away from the ends
of travel or ensure the Torque Arm is not out of position) by entering the “Setup?” Menu and
immediately exiting (by selecting “No”).
Note that the APD is a hardware device and its information is processed and stored on the
CCM. There is a processor for the APD on the CCM, so an APD error could be related to the
processor on the CCM. Firmware may have to be reloaded if there is some data corruption on
the APD Processor.

“Actuator Fail; Configuration Error” is an error that may occur if you are replacing a CCM
that has not been configured for the actuator serial number or if a configuration change was made
in the Factory Setup Menu. If during local operation for limit setting, one observes partial
movement and then receives the error message, “Actuator Fail”; “Configuration Error”, verify if
during the setting of limits the actuator was “jogging” (not continuously moving ; operating on an
interval).
This action is a discrepancy in the configuration of the bits controlling electrical and mechanical
directional travel configuration.

Check the Factory Setup Menu and the selections for the Reverse Rotation Bit and the Worm
Thread. The Drive Sleeve Output selection can be either CW or CCW dependent upon the
application, but the Reverse Rotation Bit and Worm Thread must be configured properly for the
mechanical assembly and motor gear selection (single reduction or double reduction). If not, once
one limit switch is assigned and the direction of travel is reversed the actuator may pulse
momentarily as the processor attempts to verify the configuration settings by comparing the APD
data with the configuration settings and enabled contactor selection.

If you do not have the job number or As Shipped Configuration Files to tell you the setting, you
can rotate the HW and determine which worm shaft is installed in the actuator. An actuator with
RH Worm would be CW Input at the HW to CW output at the actuator drive sleeve (input to the
valve stem if direct mount or input to aux gear assembly input shaft); an actuator with LH Worm
would be CW Input to CCW output at the actuator drive sleeve.

An actuator with CW to Close Drive Sleeve Output, Double Reduction Motor Gearing (3rd
Character of the Actuator Model Code or Development being "A-K"); and RH Worm will have the
Reverse Rotation Bit "Off".
An actuator with CW to Close Drive Sleeve Output, Single Reduction Motor Gearing (3rd
Character of the Actuator Model Code or Development being "L-Z"); and RH Worm will have the
Reverse Rotation Bit "On".
An actuator with CCW to Close Drive Sleeve Output, Double Reduction Motor Gearing (3rd
Character of the Actuator Model Code or Development being "A-K"); and LH Worm will have the
Reverse Rotation Bit "On".
An actuator with CCW to Close Drive Sleeve Output, Single Reduction Motor Gearing (3rd
Character of the Actuator Model Code or Development being "L-Z"); and LH Worm will have the
Reverse Rotation Bit "Off".

In other attempts to resolve issues that may present an “Actuator Fail” Alarm:
Check for the obvious connection issues, including verifying the security (by tightening them
down) of all the terminal screws (even those without wires visibly connected) on the MCM
Assembly Directional Control Contactor. Enter "Setup" and view the "Display Diagnostics" Menu,
particularly Alarms Log and Hardware Diagnostics. However, be aware that if the power has
been cycled the Alarm Log history will clear. See the Manual on attached link for instruction on
navigating the Menus.

http://www.eim-co.com/PDFDocs.nsf/all/E2K-405-0703/$FILE/E2K-405-0703.pdf
 If the power was cycled, did the Alarm clear and the actuator become functional? If there is
not an actual hardware failure, it may be possible to recover by power cycling. However, the
condition may repeat itself if a hardware failure is occurring even if not immediate or if
connections are loose.

If the supplied actuator has an ACM (Auxiliary Control Module) for Valve Control by Analog or
Modbus, then noise, high speed command input switching, or modulation delay settings may
result in plugging the contactor too frequently or rapidly. If it is being modulated by discrete inputs
rather than simply positioned and the contactor is being turned on and off too often by the control
source then the EFM may be set because the state of the MCM aux contacts used for motor
control input/output verification (coils held open or closed) is detected as deviating from the
current command (input) status. If the EFM watchdog timer is triggered frequently it may
eventually set the “Power Fail” Alarm. These issues may be resolved by calibration or
reconfiguration (particularly modulation delay) or replacement of the CCM. If analog control is
available or set the Analog Calibration Menus are part of the configuration. See Chapter 5 of the
Manual.

The latest revision of MCM hardware manufactured since Sept 2009 increased the Relay
size of the K3 & K4 Relays that provide the configurable electrical interlocking circuit for the K1
and K2 Coils of the electrically and mechanically interlocked Directional Control (Reversing
Contactor) of the MCM. The reason was to allow for an increase in the contact surface and spring
tension of the NC contacts of the K3 and K4 Relays further ensuring a complete circuit common
is available to the K1 Contactor and K2 Contactor Coils when either one of the K3 and K4 Relays
are enable by command from the CCM. The increased spring tension mitigates an open circuit
connection being an issue when signals are switching or momentarily enabled. Failure to pull in
the K1 Contactor and K2 Contactor Coils when a signal is provided will generate a “Power
Fail/EFM” alarm. These coils only receive power based on the contact position of the K3 and K4
relays and the availability of the command input control voltage. If there is a command and no
response to it detected by CCM (through APD updating and Aux Contact status change) the EFM
watchdog timer is set. This will drop control voltage if the condition is not cleared before the
watchdog timer parameter has been met.
These did not start entering production until June 2010.

Firmware Versions CCM 119 or higher increased the number of attempts to recover before
setting the EFM watchdog timer and “Power Fail/EFM” alarm. This allows conditions such as
frequent changes in command input or a poor contact connection at a relay to recover before
setting the EFM which will remove power from the control circuit for the MCM contactor coils.

Upgrading firmware to version CCM119 or higher will mitigate faults due to signal errors
(frequency of input switching or duration of input). A corresponding upgrade of the LDM should be
made. Check with the Factory for current production versions of the firmware as firmware
upgrades may become available from time to time as features may be implemented or
subroutines and error checking routines between modules is revised or if hardware revisions
require updated firmware.