Emerson Keystone EPI2 User manual

Installation, Operation and Maintenance Manual
MAN-10-04-100-0720-EN Rev. 2
October 2019
Keystone EPI2
Logic Board Firmware Upgrade Programmer ICD-U64 Procedure

I
Installation, Operation and Maintenance Manual
MAN-10-04-100-0720-EN Rev. 2
Table of Contents
October 2019
Table of Contents
Table of Contents
Section 1: Firmware Upgrade
1.1 Tools ............................................................................................................. 1
1.2 ICD-U64 Programmer Preparation ................................................................ 3
1.3 Firmware Update .......................................................................................... 4
1.4 Firmware Upload........................................................................................... 4
1.5 Actuator Settings Checklist ......................................................................... 16

October 2019
Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2
Firmware Upgrade
Section 1: Firmware Upgrade
This procedure details how to program rmware on the logic board for the EPI2 Actuator
using the ICD-U64 Programmer.
1.1 Tools
WARNING
Installation, conguration, commissioning, maintenance, and repairs must be performed
by approved and qualied personnel only.
NOTICE
Certain nameplates may carry more than one approval, and each approval may have
unique installation/wiring requirements and/or conditions of "safe use", installation, and
maintenance. These special instructions are in addition to and may override the standard
installation procedures. Special instructions are listed by approval type.
To update the rmware of EPI2 actuators, the following tools are necessary:
• PC with program CSSLOAD-CCS Programmer Control Software installed
(Figure 1). This software can be downloaded from:
http://www.ccsinfo.com/content.php?page=ccsloadsw
• PC with USB Drivers for all CSS programmers/debuggers
• Firmware “F02_63_125_v3_11.X.production”, for models E006, E013 or
latest revision
• Firmware “F02_250_500_v4_12.X.production”, for models E025, E051, E091,
E171 or latest revision
• The Universal programmer ICD-U64 (Figure 2)
• Logic Board or Actuator
• Cable from the ICD-U64 to the processor card rmware programming connector
part number: VA001-692-15
Figure 1
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Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2 October 2019
Firmware Upgrade
Figure 2 ICD-U64 CCS Programmer
Figure 3 EPI2 Logic Board
Table 1. Programming Connector Pinout
Signal ICD-U64 Pinout EPI2 Logic Board J15
Real Time Debugging Pin 1
ICSP Clock Pin 2 Pin 5
ICSP Data Pin 3 Pin 4
GND Ground Pin 4 Pin 3
VDD Power Pin 5 Pin 2
MCLR Pin 6 Pin 1
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Section 1: Firmware Upgrade

October 2019
Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2
Firmware Upgrade
1.2 ICD-U64 Programmer Preparation
The ICD-U64 Programmer has an internal jumper to select multiple options to power the
target board (actuator logic board).
1. ICD-U64 programmer internal jumper selecting 5V
This conguration allows the ICD-64 Programmer to provide power to the logic board.
This conguration can be used to program the logic board as standalone board or to
program the logic board while installed in the actuator. The rmware upgrade of the logic
board should be successful regardless if the logic board is powered from the actuator
power supply or ICD-U64 programmer.
2. ICD-U64 no jumper
The ICD-U64 internal jumper is not present or was set to no power the target board. It's
not possible to upgrade rmware in the logic board as a standalone board since no power
is being supplied to the target board. If the logic board is installed in the actuator, the
actuator requires to be powered on to have a successful rmware upgrade. Note that a new
programming tool will likely have this no voltage setting.
3. ICD-U64 programmer internal jumper selecting 3.3V
This option must not be selected, it is not applicable for the EPI2 Actuator.
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Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2 October 2019
Firmware Upgrade
1.3 Firmware Update
After downloading the new rmware, the actuator settings will return to their default
values. As such, the settings in place prior to the rmware download will need to be set
again. For this reason, be sure to store the actuator settings (e.g. opening speed, closing
speed, % opening torque, % closing torque). Refer to Section 6.2 (Local Conguration of
the EPI2) in the actuator IOM for details. To be clear, all settings will be returned to the
factory default values, it is necessary to reset the open/close travel limits; also, the motor
will default to the smallest size.
If not correctly reset the unit will alarm in open torque.
OM1 settings are not required to be reset because they are unaffected by the processor
card rmware ash.
1.4 Firmware Upload
This procedure is based on the CCS Inc. CCSLOAD ICD-U64 programming tool- This tool can
power the microprocessor from the USB port of the PC, using the 5V setting and also from
the actuator, using the actuators power source. The microprocessor to be ashed is referred
to as the “target”. Take care that the target is only powered from one source, not both.
In some eld installations is difcult to remove power from the actuator, this procedure
provides instructions in how to download rmware without removing the power from the
actuator, therefore instructions in the procedure must be followed to avoid any damage to
the actuator or any personal injury.
1. It is necessary to identify the position of the jumper inside the ICD-U64
programmer before downloading rmware as indicated in step 1.2.
2. To program the logic board as standalone board, connect the ICD-U64
programmer as shown in the picture and proceed in step 9.
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October 2019
Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2
Firmware Upgrade
3. To program the logic board as part of an actuator with no OM1 board present,
carefully connect the ICD-U64 programmer as shown in the pictures and proceed
in step 9.
Figure 4
4. To program the logic board as part of an actuator with an OM1 board present,
and the actuator is powered ON.
CAUTION
Accessing the electronics compartment while the actuator is in service exposes the
technician to lethal voltage and possibly from more than one source.
Set the OM1 switch SW4 in ON position, it will prevent the actuator from stroking during
rmware download, and it will allow to maintain the actuator in the last position requested
by the 4-20mA or the 0-10V loop control.
Switch SW4 in
ON position
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Section 1: Firmware Upgrade

Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2 October 2019
Firmware Upgrade
5. Note the position then remove the yellow position indicator to allow the OM1
board to be slightly moved to the side and have access to the programming
connector found in the actuator logic board.
6. Carefully remove the 4 screws that are holding the OM1 board. If the actuator is in
vertical position, there is a risk of dropping the screws inside the actuator. Dropping
the screws inside the actuator could cause a short circuit if the screws drop in the
power board, or a damage of the gears if the screws drop in the gears section.
OM1 board screws
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Section 1: Firmware Upgrade

October 2019
Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2
Firmware Upgrade
7. Once all the screws have been removed, carefully place an insulator material
underneath the OM1 board to protect the board from the metal spacers
contacting the circuit board shorting the board or I/O's to ground. Place the OM1
board slightly to the front to allow access to the programming connector in the
actuator logic board.
Insulator
Programming connector
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Section 1: Firmware Upgrade

Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2 October 2019
Firmware Upgrade
8. Carefully connect the ICD-U64 programmer. Make sure no to touch any
electrical contact.
Programming cable
9. Double click on CCSLOAD icon (Figure 1) to open programmer application (Figure 5).
Figure 5
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October 2019
Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2
Firmware Upgrade
10. Select Device.
Figure 6
11. Verify the correct rmware for the size and model of the actuator.
Table 2.
Actuator Size Firmware
063/E006 F02_63_125_v3_11.X.production.hex
125/E013 F02_63_125_v3_11.X.production.hex
250/E025 F02_250_500_v4_12.X.production.hex
500/E051 F02_250_500_v4_12.X.production.hex
1000/E091 F02_250_500_v4_12.X.production.hex
2000/E171 F02_250_500_v4_12.X.production.hex
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Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2 October 2019
Firmware Upgrade
Figure 7
12. Load the *.hex le to the CCS Device Programmer.
Figure 8
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Section 1: Firmware Upgrade

October 2019
Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2
Firmware Upgrade
13. Verify in the left window (File) of the CCS Device Programmer Screen shows the
correct Target Chip as the right window (Target Chip).
If the Target Chip eld is empty, close the application and reopen, the Target Chip
will be populated once the correct le name is loaded.
Figure 9
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Section 1: Firmware Upgrade

Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2 October 2019
Firmware Upgrade
14. Erase chip. Verify the entire chip is erased without errors.
Figure 10
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October 2019
Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2
Firmware Upgrade
15. Verify that the chip is blank.
Figure 11
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Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2 October 2019
Firmware Upgrade
16. Write to chip. Verify that the programming is complete and without errors. The
programming is now nished. The programming should take less than 30 seconds.
Remove the programing cable.
Figure 12
17. If no OM1 board is present, proceed with step 22.
18. Carefully remove the insulator material from underneath the OM1 board that
protected the board from the metal spacers.
19. Place the 4 screws back to the OM1 board. If the actuator is in vertical position,
there is a risk of dropping the screws inside the actuator. Dropping the screws
inside the actuator could cause a short circuit if the screws drop in the power
board, or a damage of the gears if the screws drop in the gears section. Carefully
replace the yellow position indicator, ensuring the indicator ngers properly
engage the position sensor.
20. Set the actuator parameters as per the IOM Manual section 6.2 Local conguration
of the EPI2 and section 1.5 Actuator Settings Checklist of this document. This is
critical for proper operation on the actuator.
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Section 1: Firmware Upgrade

October 2019
Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2
Firmware Upgrade
21. Return the switch SW4 to the OFF position- the actuator will immediately
start stroking if the new position request is different from the position before
programming the actuator.
Switch SW4 in
OFF position
22. Fill the label with the date, rmware version and technician initials, then place the
label on top of the motor.
23. Place the label indicating the rmware upgrade outside the actuator.
24. Ret the electronics enclosure cover actuator and verify correct operation.
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Installation and Maintenance Instructions
MAN-10-04-100-0720-EN Rev. 2 October 2019
Firmware Upgrade
1.5 Actuator Settings Checklist
The actuator settings will be returned to default values after a rmware upgrade.
To ensure the proper operation of the actuator the settings must be congured as referred
in the IOM Manual paragraph 6.2, Local Conguration of the EPI2 and 6.2.1 EPI2 default
general conguration. The OM1 board settings are not affected by the rmware upgrade
and it is not necessary to perform any setting changes if the OM1 is congured properly for
the application.
Collect the actuator technical information
Date
Technician Name
Model
Size
Serial Number
Firmware Version
External Label ID
Access actuator per Instructions
Upload Firmware
Place internal label on the motor
Verify Actuator Settings
Set motor parameter
Set Close limit
Set Open limit
Set L/S close by position or torque
Set L/S open by position or torque
Closing speed
Opening speed
% Closing torque
% Opening torque
Direction CW/CCW
Actuator Size/Motor setup
Blinker / Local Selector
Heater
Inversion colors LED of local control
Place external label on the actuator
Stroke actuator open and close a minimum of 3 times, to verify proper cycling
and indication
Replace electronics compartment carefully, noting the indicator/window alignment.
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Section 1: Firmware Upgrade