Troubleshooting - EMV PDF

Energy Guide
© Rolls-Royce Power Engineering plc (2012)

The information in this document is the property of Rolls-Royce Power Engineering plc. The information EG 038
may not be copied, or communicated to a third party, or used for any purpose other than that for which it is
supplied, without the prior written consent of Rolls-Royce Power Engineering plc.

Title:‐
Meggitt EMV with Moog DS2000XP controller
Troubleshooting Guide
Purpose:‐
The purpose of EG038 is to provide troubleshooting assistance to customers and field service who are faced
with rectifying in‐service faults in Electric Metering Valve (EMV) systems which were previously fault‐free and
operating normally.
This guide can also be used as a source of reference information for new or upgraded installations.
Applicable to:‐
EG038 is applicable to all Gas, Liquid and Hot Air EMVs which use the Moog DS2000XP motor controller.

Rev. Date Author

Initial 31.July.2012 R.Gibbins
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Whilst this information is given in good faith, based on the latest information available
to Rolls-Royce Power Engineering plc, no warranty or representation is given
concerning such information, which must not be taken as establishing any contractual
or other commitment binding upon Rolls-Royce Power Engineering plc or any of its
subsidiary or associated companies.
Rolls-Royce Power Engineering plc, Registered office: Moor Lane, Derby DE24 8BJ
Company number: 1305027, Registered in England Produced in Great Britain
The information in this document is the property of Rolls-Royce Power Engineering plc. The information may not be
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copied, or communicated to a third party, or used for any purpose other than that for which it is supplied, without the
prior written consent of Rolls-Royce Power Engineering plc. Page 2 of 48
Contents
1. GENERAL .............................................................................................................................................. 3
1.1 INTRODUCTION ........................................................................................................................................... 3
1.2 APPLICABILITY ............................................................................................................................................. 3
1.3 EMV EQUIPMENT SUPPLIERS ......................................................................................................................... 3
1.4 GLOSSARY .................................................................................................................................................. 4
2. EMV DESCRIPTIONS .............................................................................................................................. 5
2.1 GAS EMV (1.5 INCH AND 2.0 INCH VARIANTS) ................................................................................................. 5
2.2 LIQUID EMV (1.5 INCH VARIANT) ................................................................................................................... 7
2.3 HOT AIR EMV (4.0 INCH) ............................................................................................................................. 9
2.4 MOOG DS2000XP MOTOR CONTROLLER ....................................................................................................... 10
3. EMV OPERATION & CONTROL ............................................................................................................. 11
3.1 THE GENERAL OPERATION OF AN EMV ........................................................................................................... 11
3.2 EMV ACTUATION ...................................................................................................................................... 11
3.3 EMV INSTRUMENTATION ............................................................................................................................ 12
3.4 EMV CABLING .......................................................................................................................................... 12
3.5 EMV POWER ............................................................................................................................................ 13
3.6 EMV MOTOR CONTROLLER OPERATION .......................................................................................................... 13
3.7 EMV SYSTEM FAULT DIAGNOSTICS ................................................................................................................ 15
4. EMV SYSTEM FAULT‐FINDING ............................................................................................................. 16
4.1 BASIC SYMPTOMS OF AN EMV PROBLEM ........................................................................................................ 16
4.2 EMV FAULT‐FINDING TABLE ....................................................................................................................... 17
4.3 ACTIONS & CHECKS.................................................................................................................................... 21
5. APPENDIX – DIAGNOSTIC INFORMATION AVAILABLE FROM THE DS2000XP MOTOR CONTROLLER ...... 25
5.1 MOTOR CONTROLLER FAULT STATUS REPORTED TO THE UNIT HMI ...................................................................... 25
5.2 FRONT PANEL LED STATUS INFORMATION ...................................................................................................... 28
5.3 FRONT PANEL HMI DISPLAY INFORMATION ..................................................................................................... 29
5.4 MOTOR CONTROLLER, GUI INFORMATION ...................................................................................................... 34

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1. General
1.1 Introduction
The gas and liquid fuel metering versions of the Electric Metering Valve (EMV) were first introduced into
service on Rolls‐Royce GT applications in 2000 and have since become the standard offerings for the
Rolls‐Royce industrial fleet of Avon, RB211 and Trent applications. A further version of the EMV is also used as
the Hot Air Valve (HAV) that bleeds HP6 compressor delivery air on RB211‐DLE applications. The EMVs are
driven by motor controllers fitted inside motor boxes that act as electrical interfaces and which also provide
enclosure protection for the motor controllers. There are two distinct variants of motor box: the standard box
designed for mounting in a safe zone and the flameproof box designed for a hazardous zone.
The original EMVs contained electric actuators from Kollmorgen/Parker and used motor controllers from the
same supplier source to drive the EMVs. The original electric actuators have now been superseded by Moog
electric actuators for current production EMVs. Likewise the original motor controllers have been replaced by
the Moog DS2000XP series motor controller which is used in the current production motor boxes used on new
Rolls‐Royce GT applications.
The guide begins by providing some background information on the EMV valves and the controller and how
the system works. Section 4 then provides a matrix of the possible causes of EMV system shutdowns and the
suggested actions to test for particular faults that could cause such shutdowns.
Section 5 is an appendix detailing what status or fault information can be read directly from the DS2000XP
controller together with suggested actions against faults identified by the controller itself.
1.2 Applicability
This guide is applicable to all gas, liquid or hot air EMVs using the Moog DS2000XP controller. This covers the
new production EMVs using Moog actuators and driven by Moog motor controllers but it also covers those
in‐service combinations of original EMVs running with the current Moog motor controllers that exist due to
control system retrofits.
1.3 EMV equipment suppliers
Whittaker Controls Inc. was the original manufacturer of the EMVs introduced in the early 2000’s onto RB211
and Trent GT packages. The early Whittaker EMVs used actuators and motor controllers supplied by
Kollmorgen/Parker but later Whittaker EMVs used actuators and motor controllers supplied by Moog.
Whittaker Controls were bought by the Meggitt group in the late 2000’s and the company is now called
Meggitt Control Systems (MCS). In‐service EMVs will therefore be labelled as either Whittaker or Meggitt
valves depending on when they were delivered to site.
The original EMV systems used Rolls‐Royce motor boxes but later GT applications have used motor boxes
supplied by Meggitt which contain one or more Moog motor controllers to suit the GT application.

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1.4 Glossary
The following abbreviations, terms, definitions, etc. are used within this guide:‐
BITE ................................... Built‐In Test Equipment
ECS .................................... Engine Control System
EMI ................................... Electro‐Magnetic Interference
EMV .................................. Electric Motorised Valve
DeviceNET ........................ A type of communications link for connecting multiple devices in a network
DS2000XP ......................... The series of Moog high‐performance servo motor drive that is used as the motor
controller for Whittaker EMVs. Rolls‐Royce use the ‘power generation’ variant of
the DS2000XP.
FMV .................................. Fuel Metering Valve
HAV ................................... Hot Air Valve
Meggitt ............................. Meggitt Control Systems (MCS) is the current name for the EMV manufacturer
following the purchase of Whittaker by the Meggitt group.
Moog ................................ Moog Inc. – Industrial Controls Group. Moog are the current manufacturer of
(a) the electric actuator forming a part of each EMV and (b) the motor controller
used to position the EMV.
Motor Controller .............. The motor controller is the electric servo motor drive that controls the EMV. The
motor controller receives position demand instructions from the ECS and converts
them into electrical drive signals to the servo motor windings in the EMV.
Motor Box ........................ The motor box is an assembly comprising some form of enclosure plus one or more
EMV motor controllers. A ‘standard’ motor box is designed for operation in
non‐hazardous environments such as a control room whereas a ‘flameproof’ motor
box is designed for operation within the GT package or other site locations where
there are potentially explosive atmospheres.
PCS .................................... Plant/Package Control System
PSU ................................... Power Supply Unit
Servo Motor ..................... The EMV uses a brushless DC servo motor as the actuation for the valve
UCP ................................... Unit Control Panel
Whittaker ......................... Whittaker Controls Inc. was the original name for the EMV manufacturer.

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2. EMV descriptions
Section 2 provides general descriptions of each of the main types of EMV used by Rolls‐Royce
2.1 Gas EMV (1.5 inch and 2.0 inch variants)
The major components of the gas EMV are:‐
1) an electric actuator
2) a gas flow metering valve
3) an intermediate yoke assembly
The gas EMV electric actuator incorporates an electric servo motor which is driven by a dedicated motor
controller. The motor used is a 3‐phase, brushless DC type with three stator windings that are excited in order
(i.e. U‐V‐W) by the motor controller to rotate the motor output shaft in one direction. Changing the order of
excitation (i.e. U‐W‐V) therefore rotates the shaft in the other direction. The operation of the servo motor is
done by the motor controller which controls the timing and order of motor stator winding excitation as
required to control both the speed of the output shaft and its direction of rotation. An integral resolver fitted
to the motor shaft provides the motor controller with an accurate reading of the motor shaft angle relative to
the stator windings. This is necessary to allow the windings to be excited at the right time.
The gas EMV uses a linear motion, pressure‐balanced poppet valve to meter gas flow. The pressure balance is
provided by a piston on the top of the valve stem that is subject to the same gas pressure as that on the
bottom of the poppet valve. A pair of seals around the valve stem prevent any gas leakage from the valve into
the intermediate yoke assembly. A connection in the assembly housing vents the space between the valve
stem seals allowing any gas leakage past the 1st seal to be piped away to a safe area.
The linear motion of the gas valve means that the intermediate yoke assembly of the gas EMV has to convert
the multiple rotations of the servo motor output shaft to a limited linear movement. This is done by having a
ball‐screw mechanism on the motor output shaft that is attached to a coupling connected to the gas valve
stem. This ball‐screw coupling converts the rotary motion of the servo motor into a linear movement of the
gas valve poppet and thus sets the flow area of the gas valve. For a particular gas at a constant temperature
the metered gas flow is proportional to the effective area of the poppet valve and the pressure ratio across it.
There are no minimum and maximum valve travel stops as such but the valve seat effectively determines the
minimum position of the EMV whilst the maximum travel is limited by the distance between the top of the
valve stem coupling and the motor casing.
The yoke assembly takes advantage of the linear movement of the ball‐screw coupling in two ways. A pointer
arm fitted to the ball‐screw coupling provides a physical indication of linear valve travel with the end of the
pointer viewable through a window. The position scale is calibrated in tenths of an inch NOT %. The full
stroke (100%) of the 1.5” Gas Valve is 1” whereas the full stroke length of the 2” valve is 1.2”. A separate lever
assembly fitted to the ball‐screw coupling is used to actuate the closed position switch.
The gas EMV is required to provide failsafe action to close the gas EMV in the event of a loss of motor control.
This is done by means of a return spring connected between the EMV body and the ball‐screw coupling which
acts to close the gas valve. As soon as the servo motor stops providing a counterbalancing torque then the
EMV return spring forces the gas valve closed and so the gas EMV can also be considered to act as a gas Shut
Off Valve (SOV) in the package gas fuel system. The poppet valve has a hard seat which provides a metal‐to‐
metal gas seal when the valve is closed by the motor controller or the return spring, and so a degree of leakage
through a closed gas EMV in accordance with ANSI Class IV is to be expected.

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Figure 1 – Typical gas EMV (2 inch valve shown)

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2.2 Liquid EMV (1.5 inch variant)
The major components of the liquid EMV are:‐
2) a liquid flow metering valve with constant ΔP pressure regulator
3) an intermediate assembly
The liquid EMV electric actuator incorporates a similar electric servo motor to that of the gas EMV and which is
controlled in a similar way by a dedicated motor controller.
The Whittaker liquid EMV uses a rotary sleeve valve to meter liquid flow. For a particular liquid the metered
liquid flow is proportional to the effective area of the sleeve valve and the pressure difference across it.
Pressure compensation to make the liquid EMV delivery independent of the delivery pressure is achieved by
means of a separate pressure regulator. This spills excess inlet flow back to the LP side of the liquid fuel
system to maintain a constant pressure difference across the sleeve valve. With a constant pressure
difference across the valve (designed to be between 110‐120psid), metered liquid flow is proportional to
sleeve valve area alone.
The rotary sleeve valve requires less than 90° of rotation between the closed and maximum flow area
positions and so the multiple rotations of the servo motor shaft have to be converted to a limited rotary
motion of about a quarter turn. This is done by a step‐down gearbox in the electric actuator assembly that
effectively converts the servo motor into a limited rotation actuator.
Like the yoke assembly of the gas EMV, the intermediate assembly on the liquid EMV provides a physical
indication of liquid valve rotation and actuation of the closed position switch. In this case the pointer arm is
connected to the coupling linking the actuator output shaft to the sleeve valve input shaft and so provides an
indication of valve rotation. Likewise the closed position switch is actuated by rotary movement of a lever
connected to the same shaft coupling.
Unlike the gas EMV, the sleeve valve doesn’t have a valve seat or other features to limit rotation and so the
intermediate assembly includes both a minimum position stop and a maximum position stop in the form of
adjustable bolts that use a cam feature on the shaft coupling to limit the rotation of the sleeve valve.

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Figure 2 – Typical liquid EMV (1.5 inch valve shown)

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2.3 Hot Air EMV (4.0 inch)
The major components of the Hot Air EMV are:‐
2) a Hot Air Valve (HAV)
3) an intermediate yoke assembly
The hot air EMV electric actuator incorporates a similar electric servo motor to that of the gas EMV and which
is controlled in a similar way by a dedicated motor controller.
The linear motion of the valve means that the intermediate yoke assembly of the hot air bleed EMV has to
convert the multiple rotations of the servo motor output shaft to a limited linear movement. This is done by
having a ball‐screw mechanism on the motor output shaft that is attached to a coupling connected to the valve
stem. This ball‐screw coupling converts the rotary motion of the servo motor into a linear movement of the
valve and thus sets the flow area of the valve.

Figure 3 – Hot Air Bleed Valve

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2.4 Moog DS2000XP motor controller
The photograph below shows the cold‐plate version of the Moog motor controller. This uses the large
mounting plate as a heat sink that transfers the heat generated by the drive out through the enclosure wall of
the EMV motor box. This arrangement allows cold‐plate Moog controllers to be mounted in the flameproof
variant of the motor box which are sealed and unventilated with no internal air cooling. Standard variants of
the EMV motor box are located in safe areas and so they may include cooling fans to circulate cooling air
within the motor box and around the motor controller(s).

Figure 4 – DS2000XP motor controller

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3. EMV operation & control
Section 3 covers the basic control configuration of an EMV and how it is typically operated.
3.1 The general operation of an EMV
Each EMV is a flow metering assembly comprising a Fuel Metering Valve (FMV) or Hot Air Valve (HAV) with an
electrically actuated servo motor that provides the necessary linear or rotary actuation to the valve via some
form of gearing. Each EMV position demand signal comes from the Engine Control System (ECS) controller
which changes the position demand to control (a) an engine fuel flow or (b) a compressor bleed airflow.
The EMV is driven by its own high power motor controller (i.e. the Moog DS2000XP) that controls the rotation
of the electrical servo motor. The motor controller includes a closed loop position controller that compares
the calculated position of the metering valve against its demanded position and then drives the electrical servo
motor in the direction that minimises the position error.

Figure 5 – EMV control loop
3.2 EMV actuation
The servo motor used is a 3‐phase, brushless DC type with three stator windings that are excited in order
(i.e. UVW) by the motor controller to rotate the motor output shaft in one direction. Changing the order
of excitation (i.e. UWV) therefore rotates the shaft in the opposite direction. The servo motor is driven by
the motor controller which controls the timing, order and duration of motor stator winding excitation as
required to control both the speed of the output shaft and its direction of rotation. The resolver fitted to the
servo motor shaft provides the motor controller with an accurate reading of the motor shaft angle relative to
the stator windings. This reading is necessary to allow the windings to be excited at the right time.

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3.3 EMV instrumentation
Rather than measure EMV valve position directly with a limited rotation sensor, instead the rotational position
of the servo motor is measured by a resolver than provides an accurate measurement of the servo motor shaft
angle. The percentage travel of the EMV valve is then calculated within the motor controller by counting the
number of revolutions of the servo motor from its ‘home’ position where ‘home’ corresponds to the EMV’s
minimum or closed position. It is the calculated EMV valve travel that is used in the closed loop position
controller to drive the electrical servo motor towards the EMV demanded position.
A ‘closed’ position switch fitted to the EMV valve/actuator linkage mechanism provides an independent
indication that a valve is closed. The switch is actuated when the valve reaches the (almost) closed position.
The EMV servo motor of the valve incorporates a thermistor, which can be used by the motor controller to
monitor motor temperature and thus provide motor over‐temperature protection as part of its BITE.
3.4 EMV cabling
3.4.1 DeviceNet control configuration
Most installations of the Moog actuated EMV with DSP2000XP controller incorporate a DeviceNet network
communications link to the ECS. The purpose of this network link is to pass the valve position demand and
position feedback values between the ECS and the motor controller as well as passing a series of motor
controller fault status bits to the ECS for fault annunication indication. If the unit uses a number of EMVs for
engine control (e.g. dual fuel or DLE applications) then only a single DeviceNet link is needed to chain all the
EMV motor controllers together and connect them to the single ECS DeviceNet interface.
The main cables between the ECS, motor controller and EMV are designated as follows in this guide:‐
 Cable D carries the network communications between the ECS and the EMV(s)
 Cable E carries the discrete ‘enable’ signal to the motor controller that allows closed loop position control
 Cable F returns the discrete ‘controller fault’ condition from the motor controller to the ECS
 Cable P provides the controller with its power supply
 Cable M provides the power drives to the 3 servo motor windings
 Cable R carries the resolver excitation signal and the separate resolver SIN and COS return signals that are
used to calculate servo motor angular position
 Cable T carries a servo motor temperature signal to the controller
 Cable S returns the discrete ‘valve closed’ condition to the ECS

Figure 6 – EMV cabling with DeviceNet control

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3.4.2 Analogue control configuration
Some installations (e.g. the FT55 Trent control systems) do not utilise a network communications link between
the ECS and the controller but use analogue signals for position control. Instead of sending number values, the
valve position demand from the ECS is sent as a 4‐20mA signal to the controller (cable A1) and the valve
position feedback is returned to the ECS as a 4‐20mA signal (cable A2). With no communications link then no
detailed fault status information from the controller can be reported to the ECS other than the common fault
status indicated by the controller’s hardwired fault contact (cable F).
With the exception of the analogue position demand and feedback signals carried by cables A1 and A2, the
cabling for all other EMV system functions is the same as that described previously in section 3.4.1.

Figure 7 – EMV cabling with analogue control
3.5 EMV power
There are several configurations with regards to the design of the power supply to the EMV controller(s). The
project specific schematics should always be used as the reference for troubleshooting.
Typically, the EMV controllers are powered from, two off 144VDC power supply units (PSU) connected in
Parallel via a Diode pack. Each PSU is a dual 72VDC power supply feed from either a 24Vdc or 240VAC supply.
The two 72VDC outputs of a single PSU are connected in series to provide the 144VDC output to the Diode
pack. Typically each PSU has its own fuse, normally a 10A fuse would be used for units which are 24VDC
powered.
Although one PSU may be able to provide adequate power for two controllers under normal steady state
conditions, the two PSU’s are not intended to offer system redundancy. Both PSU’s must be in operation for
the system to work reliably.
When checking the output of the each PSU, the other PSU should be powered down to ensure that the checks
conducted on the PSU under test are not influenced by the other PSU.

3.6 EMV motor controller operation
3.6.1 Enabling the motor controller
The Moog DS2000XP motor controller has an ENABLE input which must be energised with a 24VDC signal for
the controller to be able to carry out closed loop position control of the EMV. If the ENABLE signal is lost or
removed for any reason then the motor drive signals are switched off and the EMV is forced to its minimum
valve position by the action of its failsafe return spring.

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The ENABLE input to the controller will typically be sent via the hardwired contacts of one of a number of
shutdown relays that are controlled by the trip string of the unit control system. A broken trip string will
disable the EMV by opening the contacts on the EMV shutdown relay and removing the ENABLE. Any standing
unit shutdown that has broken the trip string will mean that the ENABLE signal cannot be received by the
controller. This means that an EMV cannot be stroked for test purposes with a standing shutdown.
All unit shutdowns should normally be cleared first before stroking an EMV for test purposes but if it is
absolutely necessary to stroke the EMV while the unit remains in a tripped state then jumper around the EMV
shutdown contact so that the controller can be enabled for stroking. Any such jumper MUST be removed prior
to any start or crank of the unit. (It is NOT recommended that a slave 24Vdc supply be used.)

Figure 8 – A typical EMV enable/fault configuration

3.6.2 Reset of the motor controller
The Moog motor controller has no separate RESET input. Instead, the energising of the ENABLE input acts as
the reset command. If the controller is already powered up and enabled then a reset command requires that
the ENABLE input signal be removed and then reapplied because it is the transition of the ENABLE input from
OFF to ON that resets the controller. Typically the UCP will provide a RESET relay in parallel with the EMV
shutdown contact to allow any motor controller faults to be reset and cleared which would otherwise keep the
motor controller disabled and locked out.
3.6.3 Motor controller power‐up
Upon completion of the initial power up sequence, the motor controller will be in a fault condition with the
panel LED #1 (RED) lit and the fault o/p to the ECS signalling an ‘EMV controller fault’ condition. Assuming
there are no EMV faults, the controller requires a reset command to clear the fault condition. If the controller
has been reset and is running OK then no panel LED’s should be lit. Once the controller becomes activated
with the application of the ENABLE signal and is running fault‐free then panel LED #4 (GREEN) will be lit.

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3.7 EMV system fault diagnostics
3.7.1 Controller fault relay
The motor controller contains Built‐In Test Equipment (BITE) which carry out self‐diagnostics as well as
monitoring the EMV system for particular fault conditions. If BITE detects any motor controller or EMV system
fault then it puts the controller’s ‘EMV controller fault’ relay into the fault condition. The ECS monitors the
status of the EMV controller fault’ relay and if the N/O contacts are open (closed contacts indicate a healthy
controller) then the ECS assumes there is an EMV system fault. The ECS is programmed to trigger a unit
shutdown in the event of an EMV system fault and so the hardwired controller fault contact is the primary
trigger of a unit shutdown if there is an EMV system fault. The presence of a standing EMV system fault will
also prevent a unit start.
3.7.2 Status flags sent via DeviceNet link
Where the ECS is linked to the EMV via a DeviceNet communications link then additional fault information
from the motor controller can be supplied to the ECS as individual fault flags. These flags can be sent to the
HMI for local display or interrogated within the ECS itself. Where a DeviceNet link is not used for command
communications (e.g. the FT55 Trent control systems) then this additional fault information can’t be passed to
the ECS or the HMI. For such motor controllers using analogue position demand & feedback links then
additional fault information can only be accessed directly from the motor controller itself.
3.7.3 Controller panel HMI
The motor controller fascia panel has a number of LEDs which can provide basic controller status information
but the LEDs are quite limited in what they can tell you. More usefully, the motor controller also has a local
HMI panel with an LCD display and some pushbuttons allowing navigation by menu. This local HMI can be
used to display the detected controller faults from a defined list of fault conditions. (The same HMI can be
used to display other menus that allow the motor controller configuration parameters to be checked or
adjusted.)
3.7.4 Controller GUI1
If necessary the motor controller can also be connected directly to a PC via a communications link to a comms
port on the motor controller. If the PC has the appropriate Graphical User Interface (GUI) software to match
the Moog DS200XP controller then the status of the motor controller can be interrogated from the PC. The
GUI provides access to similar lists of configuration parameters and fault status flags as the controller’s front
panel display but it provides more comprehensive coverage. (See Table 5 and Table 6 for fault listings). The
GUI will also allow data‐logging of control parameters directly from the motor controller to the PC. These logs
can be inspected later for fault diagnosis.
3.7.5 ECS position error check
All necessary self‐diagnostics and condition monitoring for an EMV can be done by the motor controller BITE
alone. However, as an independent check of EMV function, the ECS does monitor EMV position error based on
the difference between the ECS position demand & feedback values. If EMV position error measured by the
ECS goes outside of the specified limits then the ECS will trigger a unit shutdown, even if the motor controller
fault relay still indicates a healthy condition.
3.7.6 EMV position switch
The ‘valve closed’ position switch contacts on the EMV are monitored by the Plant Control System (PCS). The
switch provides independent confirmation that the EMV valve is closed when expected rather than relying
entirely on the valve position calculated by the motor controller. This position switch is therefore typically
used within the PCS start sequence logic as a start permissive, i.e. the start sequence is aborted if the switch
indicates the EMV is not closed when it ought to be during the start.

1
Refer to document LSF 0577 “DS2000XP Graphical User Interface Manual” (Moog Industrial Controls Division) for information on
installing & using the Moog motor controller GUI.

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4. EMV system faultfinding
This guide is intended for troubleshooting problems with an EMV that has been successfully installed &
commissioned but which is now causing unit shutdowns or preventing unit starts.
4.1 Basic symptoms of an EMV problem
There are three basic fault conditions in an installation that will cause a previously healthy EMV to stop
working and either trip the unit or else prevent unit starts:‐
1. If the “EMV controller fault” relay operated by the motor controller signals a fault condition then
the ECS is programmed to shutdown the unit.
The hardwired fault contact of a motor controller provides a robust method of providing indication to
the ECS and operator that controller has detected a fault. Although the alarm is issued by the motor
controller, the fault may not be related to the controller itself and may instead indicate a valve or
wiring problem.
On initial power‐up of a controller, the hardwired fault contact will be in an unhealthy state until
communications have been established and the controller has been reset i.e. when LED1 no longer
displays red. The controller does not have an independent reset coil, a reset of the controller is
achieved by toggling the ENABLE input. A fault on the enable circuit to the controller may mean that
the controllers don’t reset after power‐up.
The hardware contact provides indication of a common fault detected by the controller and will
normally be accompanied by any of the controller status bits sent via DeviceNet (where applicable)
are unhealthy, but is not limited only to these status bits.
2. If the EMV motor controller uses a DeviceNet communications link and this communications link is
lost then the ECS is programmed to shutdown the unit.
The ECS monitors a watchdog status bit sent over the DeviceNet link. If the watchdog check fails then
command and control of EMV is assumed lost and the ECS must shutdown the unit.
3. If the ECS detects that the error between the position demand and actual position values within the
ECS is out‐of‐limits then the ECS is programmed to shutdown the unit.
The ECS continuously performs a position error check by comparing the valve actual position against
the setpoint. An error of more than X% for Y seconds will generate this shutdown2.
A position error shutdown occurring while the unit is running may suggest that either drive to the
valve has stopped or the valve has stuck in position. The HMI Historical Trend or data logs can be
checked to determine if the valve maintained position or dropped suddenly. If the valve held
position, valve stiction is likely and a stroke test of the valve should be conducted. If the valve appears
to have closed rapidly before the setpoint, drive to the valve may have failed.

For fault cases 1, 2 and 3 above, the ECS shuts down the unit by de‐energising and/or breaking the continuity
of the hardwired trip string in the Unit Control Panel (UCP) thus removing the ENABLE signal to the motor
controller. (Other dedicated unit trips can break the trip string which has the same effect in removing the
ENABLE signal but these are not flagged up as EMV shutdowns). Without the ENABLE signal present, a
disabled motor controller switches off the drives to the EMV motor, allowing the failsafe action of the EMV
return springs to close the valves.
There are numerous faults that can cause one of the three fault conditions listed above to occur. The tables
included in the rest of section 4 can be used to trace the fault and suggest remedial action to restore the
system where applicable. In some cases the only action possible will be the replacement of the EMV or its
motor controller.

2
The typical test criteria for an EMV position error shutdown are a >5% error persisting for >5 seconds. However, the particular position
error test values in an ECS can differ between engines and applications so service personnel should always confirm what the correct test
settings should be for position error detection.

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4.2 EMV Fault‐Finding Table
The following table provides a list of symptoms due to particular EMV system faults which may be encountered in‐service.
Against each possible EMV fault the table lists the suggested service action to check if that particular fault is the cause of the EMV system problem. More detail on particular service
actions can be found in section 4.3. Although descriptions may vary slightly from installation to installation, the possible cause and suggested actions will be similar. Any EMV related
fault which has been identified by the control system or controller should result in one of the shutdowns tabled below. Where a unit has tripped either during normal operation or
while on standby, the chart below should be used in the first instance for identifying the possible cause and suggested action.

Table 1 – EMV system fault‐finding
Symptom Possible Fault / Explanation Suggested Action
S1 Gas EMV reported as inoperative A1 Check whether the gas EMV can be stroked normally or not.
Gas EMV position switch fault If the gas EMV can be stroked normally, check the wiring &
A2 function of the position switch
Gas EMV valve fault If the gas EMV can be stroked normally, check if the EMV
A3 flows any gas when stroked fully open. If the actuator valve
can be driven open but no gas flows there is a valve fault.
Gas EMV actuator wiring fault If the gas EMV can’t be stroked, check the wiring to the EMV
A4 actuator.
S2 Liquid EMV reported as inoperative Check whether the liquid EMV can be stroked normally or
A5 not.
Liquid EMV position switch fault If the liquid EMV can be stroked normally, check the wiring &
A6 function of the position switch
Liquid EMV valve fault If the liquid EMV can be stroked normally, check if the EMV
flows any liquid when stroked fully open. If the actuator
A7 valve can be driven open but no liquid flows there is a valve
fault.
Liquid EMV actuator wiring fault If the liquid EMV can’t be stroked, check the wiring to the
A8 EMV actuator.
S3 Drift in the Liquid EMV flow calibration Liquid valve DP pressure regulator fault A9 If the LFMV can’t maintain a constant DP then the regulator

EG 038

Fouling of the DP regulator is faulty or fouled. Replace the regulator
S4 HAV reported as inoperative A10 Check whether the HAV can be stroked normally or not.
HAV control circuit fault If the HAV can be stroked normally but is not fully closed
A11 when de‐energised, check the HAV control function. Also
check if the HAV thermostat has cut in.
HAV valve fault If the HAV can be stroked normally, check if the HAV flows
A12 any air when stroked fully open. If the actuator can be driven
open but no air flows there is a valve fault.
HAV actuator wiring fault If the HAV can’t be stroked, check the wiring to the HAV
A13 actuator.
S5 ECS SHUTDOWN EMV controller is in fault A14 Check for faults on the unit HMI or the controller.
(LSS65UC044, LSS65UC045, LSS65UC046)
Wiring fault with motor controller fault Check if other related EMV related faults are present. If this
Metering Valve Failure
contact is the case the fault is most likely genuine and not wiring
Central / Primary / Secondary EMV
fault with the controller fault contact.
If the “fault” circuit isn’t OK then it can send a
This ECS shutdown indicates a common fault has
false signal of a controller fault to the ECS Verify the wiring between the ECS Digital Input (DI) card and
been signalled by one of the DS2000XP motor the controller.
controllers. The shutdown is determined from
an unhealthy condition of the hardwired fault Jumper the fault contact terminals at the controller and
contact of the motor controller in fault. verify that the shutdown clears.
ECS Digital Input (DI) card fault Check if other related EMV related faults are present. If this
is the case the fault is most likely genuine and not wiring
fault with the digital input card.
Jumper the fault contact terminals at the controller and
verify that the shutdown clears.
DeviceNet communications fault Check for DeviceNet Communications SD. The metering
valve fault will always come up when there is a standing
DeviceNet communications fault.
EMV Motor Drive Wiring fault Inspect the motor drive wiring between controller and EMV.

EG 038

EMV Resolver Wiring fault Inspect the motor resolver wiring between the controller and
the EMV.
Verify resolver resistors are fitted.
S6 ECS SHUTDOWN Power‐up sequence error Disconnect the DeviceNet cable at the ECS DeviceNet card,
(LSS65UC001, LSS65UC002, LSS65UC003) wait 60 seconds and reconnect. Allow 60 seconds for
Where the DS2000XP and / or ECS Rack has
Device Net Communications Failure communications to re‐establish.
been powered off and back on, the power‐up
Central / Primary / Secondary EMV
sequence can result in lost communications.
Applicable to FT125 applications only.
This ECS shutdown means that the DeviceNet
communications between the ECS and the
DeviceNet wiring fault For new installations, verify correct DeviceNet wiring
Moog DS2000XP controller(s) have stopped.
between the ECS rack and DS2000XP. Including cable
The shutdown is determined from a status bit
specification.
received by the ECS over DeviceNet from the

DS2000XP. Inspect for loose connections and trapped insulation,
damaged cable insulation.
Verify that a 120 Ohm termination resistor is fitted at each
end of the DeviceNet trunk line.
Controller power failure Verify 144V DC power at controller(s). Confirm each PSU is
providing 144V DC output.
This shutdown will occur if power to the
DS2000XP is lost.
DeviceNet Bus voltage fault Verify 24V DC on the Pos (Red) and Neg (Black) of the
DeviceNet network.
Motor controller fault Review Controller faults on DS2000XP LCD and Moog GUI.
ECS Rack DeviceNet card or configuration Verify that the DeviceNet configuration is correct and if
fault necessary replace the card.
S7 ECS SHUTDOWN Valve sticking Check HMI Historical Trend or data logs where available for
(LSS65UC115, LSS65UC116, LSS65UC117) signs of the valve actual position holding position and failing
Valve Position Error Failure to track the setpoint.

EG 038

Central / Primary / Secondary EMV Stroke check the EMV, ensuring that the feedback tracks the
setpoint. Verify that the position indicator on the valve also
The ECS continuously performs a position error
track the demand signal.
check by comparing the valve actual position
against the setpoint. An error of more than 5% Listen for an audible knock or chattering of the EMV while
for 5 seconds will generate this shutdown stoking it.
If the EMV has elapsed 50K hours, replace the valve.
Controller ENABLE lost Check the controller ENABLE signal wiring
Set the valve stroke enable in the ECS software and check for
24V DC and the enable contact of the controller.
Controller power interruption Check the 144VDC power supplies.
Controller fault Check for other Controller related faults.

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A3 Gas EMV Visual Position Indicator Moves Normally – No Significant Gas Flow
4.3 Actions & Checks When Open
(a) With the actuator energized, the position indicator shows the valve is in the
Gas EMV valve checks fully open position, but there is no measurable gas flow.
A1 Gas EMV Reported Inoperative (b) At several open positions, if there is no measurable fuel flow greater than the
permitted leakage flow (0.10 pound or 45g per minute), return the valve to
(a) Visually check for valve operation by observing for movement of the visual Meggitt for repair.
position indicator when the valve is cycled (energized and de‐energized).
(b) If visual position indicator moves normally, proceed to actions A2 and A3. If the A4 Gas EMV Visual Position Indicator Will Not Move – Possible Actuator Fault
visual position indicator does not move normally, proceed to action A4. (a) Remove the screws securing the actuator motor terminal block junction box
cover. Check/verify that all wiring connections are correct and that the terminal
A2 Gas EMV Visual Position Indicator Moves Normally – Possible Position screws are tight. Check for continuity between the junction box terminals and
Indicating Switch Fault the motor amplifier connector. Locate and correct any external circuit faults.
(a) With the actuator de‐energized, visually verify that position indicator shows the
valve is in the fully closed position. If the visual position indicator shows the Important! Be sure that power is off prior to opening the EMV’s junction
box or touching the electrical wires.
valve partially open and there is excessive leakage flow (more than 0.10 pound
[45 g] per minute), return the valve to Meggitt for repair. (b) Remove power and disconnect the electrical power input lead wires from
(b) Remove the screws securing the closed position indicating switch junction box terminals 1, 2 and 3 of the terminal block. If the actuator is hot, allow sufficient
cover. time for the windings to cool to room temperature (60 to 80°F [16 to 26°C]).
(c) With the actuator de‐energized and the visual position indicator showing the (c) Measure the resistance between terminals 1 and 2 (Brown‐Red), terminals 1
valve in the fully closed position, verify that continuity exists between the C and and 3 (Brown‐White), and terminals 2 and 3 (Red‐White) of the terminal block.
NC switch terminals. If an open circuit exists, manually actuate the closed With the motor windings at room temperature, each resistance value must be
position indicating switch while monitoring for continuity between the C and 0.288 ohms (±10%). If the resistance value is satisfactory, reconnect the
NC switch terminals. electrical power input lead wires to terminals 1, 2 and 3 (tighten the terminal
screws to within 3.5 to 5.3 inch‐pounds [0.4 to 0.6 Nm] torque) and proceed to
(d) If the closed position indicating switch functions normally (opens and closes), step D below. If the resistance value is not within the specified limits, return
adjust the switch to close when the valve is within 0.020 inch (0.51 mm) from the valve to Meggitt for repair.
the fully closed position. If the switch will not function or cannot be adjusted,
replace the switch. (d) Measure the resistance of the resolver coils. The resistance values must be as
follows:‐
(e) Energize the actuator and verify that the closed position indicating switch
operates correctly.  Red/White to Yellow/White (E to F) ................................. 24.3 ‐ 34.1 ohms
 Red to Black (A to B) ............................................................ 57.6 ‐ 99 ohms
 Yellow to Blue (C to D) ......................................................... 57.6 ‐ 99 ohms

EG 038
If any of the resistance values is not within the specified limits, return the valve (d) If the closed position indicating switch functions normally (opens and closes),
to Meggitt for repair. adjust the switch to close when the valve is within 4 to 6 degrees from the fully
closed position. If the switch will not function or cannot be adjusted, replace
(e) Measure the resistance of the motor coils. With the motor windings at room
the switch.
temperature, the resistance must be as follows:
(e) Energize the actuator and verify that the closed position indicating switch
 Brown wire to Red wire ................................................... 0.288±10% ohms
operates correctly.
 Red wire to White wire .................................................... 0.288±10% ohms
 White wire to Brown wire ................................................ 0.288±10% ohms
A7 Liquid EMV Visual Position Indicator Moves Normally – No Significant Fuel
(f) If the wiring connections and the resistance values are verified to be correct, Flow When Open
and the valve still will not operate, return the valve to Meggitt for repair.
(a) With the actuator energized, the position indicator shows the valve is in the
fully open position, but there is no measurable fuel flow.
Liquid EMV valve checks
(b) At several open positions, if there is no measurable fuel flow greater than the
A5 Liquid EMV Reported Inoperative permitted leakage flow (0.6 gpm or 2.27 l/min), return the valve to Meggitt for
repair.
(a) Visually check for valve operation by observing for movement of the visual
A8 Liquid EMV Visual Position Indicator Will Not Move – Possible Actuator Fault
(b) If visual position indicator moves normally, proceed to actions A6 and A7. If the
(a) Remove the lock screws securing the actuator motor terminal block junction
visual position indicator does not move normally, proceed to action A8.
box cover, unscrew the cover. Check/verify that all wiring connections are
correct and that the terminal screws are tight. Check for continuity between
A6 Liquid EMV Visual Position Indicator Moves Normally – Possible Position
the junction box terminals and the motor amplifier connector. Locate and
Indicating Switch Fault
correct any external circuit faults.
valve is in the fully closed position. If the visual position indicator shows the Important! Be sure that power is off prior to opening the EMV’s junction
valve partially open and there is excessive leakage flow (more than 0.6 gpm or box or touching the electrical wires.
2.27 l/min), return the valve to Meggitt for repair.
(b) Remove power and disconnect the electrical power input lead wires from
(b) Remove the screws securing the closed position indicating switch junction box terminals U, V and W of the terminal block. If the actuator is hot, allow
cover. sufficient time for the windings to cool to room temperature (60 to 80°F) (15 to
27°C).
(c) With the actuator de‐energized and the visual position indicator showing the
valve in the fully closed position, verify that continuity exists between the C and
NC switch terminals. If an open circuit exists, manually actuate the closed
position indicating switch while monitoring for continuity between the C and
NC switch terminals.

EG 038
(c) Measure the resistance between terminals U and W (Black), terminals U and V (b) If visual position indicator moves normally, proceed to actions A11 and A12. If

(Black‐White), and terminals V and W (Red‐White) of the terminal block. With the visual position indicator does not move normally, proceed to action A13.
the motor windings at room temperature, each resistance value must be 4.9
ohms (±10%). If the resistance value is satisfactory, reconnect the electrical A11 HAV Visual Position Indicator Moves Normally ‐ Possible Control Circuit Fault
power input lead wires to terminals U, V and W (tighten the terminal screws to
within 3.5 to 5.3 inch‐pounds [0,4 to 0,6 Nm] torque) and proceed to step D
valve is in the fully closed position. If the visual position indicator shows the
below. If the resistance value is not within the specified limits, return the valve
valve partially open and there is excessive leakage flow.
to Meggitt for repair.
(b) From the controller, check all of the fault indicators for normal indications.
(d) Measure the resistance of the resolver coils. The resistance values must be as
Make sure that the valve is correctly commanded and that there is not a
follows:‐
feedback or communication problem.
 Red/White to Yellow/White .......................................... 24.3 to 34.1 ohms
(c) Check the valve thermostat circuit for continuity. If the thermostat is open,
 Red to Black ....................................................................... 57.6 to 99 ohms
allow sufficient cooling time for it to reset. If the thermostat will not reset.
 Yellow to Blue .................................................................... 57.6 to 99 ohms
return the valve to Meggitt for repair.
If any of the resistance values is not within the specified limits, return the valve
to Meggitt for repair. A12 HAV Visual Position Indicator Moves Normally ‐ No Significant Gas Flow When
Open
(e) If the wiring connections and the resistance values are verified to be correct,
and the valve still will not operate, return the valve to Meggitt for repair. (a) With the actuator energized, the position indicator shows the valve is in the
fully open position, but there is no measurable gas flow.
A9 Liquid EMV fails to maintain 90‐120 psid between Pin and Pout, and the flow
(b) At several open positions, if there is no measurable gas flow greater than the
characteristic drifts from standard.
permitted leakage flow, return the valve to Meggitt for repair.
(a) Where the fuel particulate contamination is known to be an issue, the pressure
regulator can become clogged, seize and cease to function. A13 HAV Visual Position Indicator Will Not Move – Possible Actuator Fault
(b) The preferred course of action is to return the valve to Meggitt for overhaul. (a) Access the electrical connections at the external terminal block. Check/verify
that all wiring connections are correct and that the terminal screws are tight.
(c) The alternative action to (b) is to purchase a replacement regulator
Check for continuity between the terminals and the motor amplifier connector.
(C236825‐1) and replace per part 3 of the REPAIR section in the C236765
Locate and correct any external circuit faults.
manual.
Important! Be sure that power is off prior to opening the EMV’s junction
Hot Air Valve (HAV) checks box or touching the electrical wires.
A10 HAV Reported Inoperative (b) Remove power and disconnect the electrical power input lead wires from
terminals. If the actuator is hot, allow sufficient time for the windings to cool to
(a) Visually check for valve operation by observing for movement of the visual
room temperature (60 to 80°F [16 to 26°C).

EG 038
(c) Measure the resistance of the motor coils. With the motor windings at room controller. The removed controller will need to be returned to the supplier for repair.
temperature, the resistance must be as follows:‐ If the BITE identifies an external fault as the cause of the problem then, depending on
what the fault is, it should be possible to restore the system to health by fixing the
 Brown wire to Red wire .......................................................... 0.4 Ω (±10%)
external fault.
 Red wire to White wire .......................................................... 0.4 Ω (±10%)
 White wire to Brown wire ....................................................... 0.4 Ω (±10%)
If the resistance value is satisfactory, reconnect the electrical power input lead
wires to their assigned (tighten the terminal screws to within 3.5 to 5.3 inch‐
pounds torque) and proceed to step D below. If the resistance value is
significantly outside of the specified limits, return the valve to Meggitt for
repair.
(d) Disconnect and measure the resistance of the resolver coils. The resistance
values must be as follows:‐
 Red/White wire to Yellow/White wire ................................ 24.3 Ω ‐ 34.1 Ω
 Red wire to Black wire ............................................................ 57.6 Ω ‐ 99 Ω
 Yellow wire to Blue wire ......................................................... 57.6 Ω ‐ 99 Ω
If any of the resistance values is significantly outside of the specified limits,
return the valve to Meggitt for repair.
EMV motor controller checks
A14 Interrogate motor controller diagnostics
Upon any indication that a motor controller is in a genuine fault condition, all the
following motor controller diagnostics (where available) should be inspected to find
out if the motor controller BITE has identified the particular fault condition that has
put the controller into fault:‐
(a) Unit HMI status (refer to section 5.1 for details)
(b) Front Panel LEDs (refer to section 5.2 for details)
(c) Front Panel HMI Display (refer to section 5.3 for details)
(d) Motor controller GUI (refer to section 5.4 for details)
If the motor controller BITE detects an internal controller fault as the cause of an EMV
shutdown then the only way to restore the EMV system is to fit a replacement motor

EG 038
5. Appendix – Diagnostic information available from the DS2000XP Motor Controller
5.1 Motor controller fault status reported to the unit HMI
The following table lists the EMV controller faults which are reported on the FT210 HMI. These HMI flags are based on the controller fault status information supplied over the
DeviceNet network to the ECS. This EMV fault information is only available on the HMI if the EMV is connected with a DeviceNet communications link.
Table 2 only lists the most commonly detected faults within the controller. The motor controller can detect a number of other faults which are not reported to the HMI but which
trigger a shutdown via the hardwired “EMV fault” relay contact on the controller.

Table 2 – EMV fault status information reported to the unit HMI via DeviceNet
Unit HMI Controller Fault Description Action
Flags that the DeviceNet communications between the ECS
EMV DeviceNet Communications and the Moog DS2000XP controller(s) have stopped. The

Failure shutdown is determined from a status bit received by the ECS
over DeviceNet from the DS2000XP.
Detects the BUS overvoltage condition;
the drive cuts off the current. This can be due to a recovery
EMV Bus Overvoltage Fault resistance interruption or the resistance value is too high for a. Check 144VDC bus supply voltage meets the specification.
the application and it cannot dissipate the energy recovered b. Verify the drive configuration parameters “motor bus voltage
by the motor and the drive. (drv.mtrbus)” = 110.
Detects the BUS undervoltage condition; c. Verify there is no Connection to Recovery Resistor on the Drive.
the drive cuts off the current. This can be d. Check for faulty 24V‐>144VDC supply.
EMV Bus Undervoltage Fault e. Check for an Actuator drawing too much current.
due to a power line interruption or to an excessive current
absorption by the drive with respect to the resistance f. Possible Faulty Drive; Replace the Drive.
Detects the lack of DC BUS or a value lower than 80 V
EMV No Bus Voltage Fault
(minimum default factory set value).
EMV Bus Voltage Rate of Change
EMV Bus Reading Fault
a. Verify the drive fan is working if the drive fan exists.
Indicates the drive heat‐sink over‐temperature. This can be
caused by the drive operating with current higher than the b. Check current draw of actuator for abnormally high current
EMV Drive Overtemperature Fault drive can supply. This may also be an indication of improper levels. If levels are high replace the actuator.
drive cooling. c. Turn off drive and let cool, If fault appears after cooling replace
the drive.

EG 038

a. Reload parameter set
Indicates a control cards exchange between two different size b. Verify the correct drive model number is used
EMV Drive Size Fault drives.
c. If still exists download parameters, and perform a “Save
Parameters” from the “Utility Menu”
a. Power cycle the Drive
b. If still exists download parameters, and perform a “Save
EMV EEPROM Checksum Fault Indicates an internal memory error. Parameters” from the “Utility Menu”
c. Attempt another full Power Cycle
d. Possible Faulty Drive; Replace the Drive
Indicates an error in the internal Try to switch the drive off and cut off the line. In case the FAULT
EMV Flash EEPROM Read Fault reading of the parameters memorized inside the drive; it is persists, try to re‐set parameters and save all data again; if the error
possible a reading error in the internal memory. persists the section is damaged
EMV Home LS Fault
EMV Home Time Fault
Indicates that the +15 V internal power value is out of a. Check 144VDC bus supply voltage meets the specification.
EMV +15 volt Fault b. Verify the J2B pin 1 on the control head has no connection and is
tolerance
not under load
c. If intermittent Monitor drive load under normal operation and
Indicates that the ‐15 V internal power value is out of check for abnormally high loads. If spikes occur in parallel with
EMV ‐15 Volt Fault 15 volt supply fault check actuator condition
tolerance
d. Check for excessive ambient heat
e. Possible Faulty Drive; Replace the Drive
Indicates that the max speed set inside the drive has been This fault is disabled in the DSP
EMV Motor Overspeed Fault
exceeded more than 12%.
This fault is disabled in the DSP
EMV Motor Temperature Fault Indicates the motor over‐temperature. Check the application size, during the cycle an effective current higher
than the one the motor can manage is absorbed.
EMV Position Error Fault
EMV Position Home Fault
EMV Pre Home Fault

EG 038

a. Check Resolver Wiring
b. Verify Drive Parameters drv.respoles, tstif.respoles
Indicates the presence of errors on the connection signals c. Check Resolver Supply Voltage 20VPP @ 10KHZ with no load. If
EMV Resolver Fault inside the resolver section.
incorrect voltage replace drive.
d. If Connections, parameters, and drive supply are correct replace
actuator.
a. Remove high power and allow drive voltage to dissipate.
Measure voltage at the drive input for safe working voltages
before proceeding
Detects the excess current or short circuit condition of the b. Verify system is shielded and grounded properly
output IGBT three‐phase bridge or the recovery circuit IGBT. c. Check drive outputs(U2, V2, W2) with and ohmmeter for short
EMV UVW Phase IGBT Fault This can be generated by noise from an improperly shielded
system or a shorted IGBT on the drive power stage. circuit from each output phase to all other output phases
d. Check drive outputs for phase to chassis ground short circuits.
e. If fault is permanent and the shorts are measured replace the
drive.

EG 038
5.2 Front panel LED status information
There are four LED’s on the front of the DS200XP controller which can be used to provide some basic controller diagnostic information.

Table 3 – Controller panel LED status information
1 2 3 4 Controller LED status Description Action
Controller HEALTHY but NOT ENABLED N/A – NO FAULT
    All LEDs OFF
Controller POWERED DOWN N/A – NO FAULT
This will occur at power‐up. Toggle the ENABLE input to

CONTROLLER FAULT reset the controller.
    LED #1 (RED) ON
Any fault detected by controller BITE will light LED #2 Verify that the ENABLE is toggling 24V on a UCP reset.
Check Controller Diagnostics for further information
    LED #2 (YELLOW) ON CURRENT FOLDBACK FAULT (warning or error) Check Controller Diagnostics for further information
APPLICATION CODE NOT RECOGNISED
 Perform a configuration download (refer to GUI Manual)
Model is not running, the controller may have detected a
   LED #2 (YELLOW) FLASHING
mismatch in the database on power up and then reverted
 Check Controller Diagnostics for further information
back to factory defaults.
    LED #3 (YELLOW) ON POSITION FOLLOWING ERROR Check Controller Diagnostics for further information
Check Valve controller wiring.
    LED #2 & #3 (YELLOW) ON HOMING FAULT
Check Controller Diagnostics for further information
    LED #4 (GREEN) ON DRIVE ENABLED N/A ‐ NO FAULT

EG 038
5.3 Front panel HMI display information
The Moog controller has a built in panel LCD display which may be used to provide some basic diagnostic information. This can
be particularly useful where there is no fault information available on the control system HMI but the controller has tripped on
EMV Controller Fault.
The six keys on the DS2000XP front panel allow the visualization of the whole menu as well as the relevant drive configuration.
A further key allows the display contrast adjustment.
The keys can be divided according to their function:
ENTER This key allows to enter a menu and browse it. The variables scanning inside a menu is recursive. In some cases, this
key activates a routine function (i.e. inside the ?Utility? menu).
< and > These keys allow the menu horizontal scrolling from right to left and vice versa.
+ and ‐ These keys allow to increase and decrease a variable. Holding the key down approx. 5 s the fast forward starts.
ESC This key allows to go back inside the menu or terminate a function.
 Holding down the yellow key, it is possible to adjust the display contrast by means of the + / ‐ keys. In order to keep
the setting, it is necessary to save the parameters before switching off the drive.
Notes
1. First screen at drive start‐up show you the DS2000XP size. The DRIVE ENABLE and REFERENCE ENABLE signals are shown in the start‐up screen on the display by two stylised
letters: D? and ?R? respectively.
2. The first menu level can be accessed pressing ENTER. The first level is characterized by the two < and > arrows which indicate the possibility of scrolling the menu from right to
left. Once in the first menu level, to access the Fault Detection menu, press the > key until “Fault Detection” is displayed and press ENTER. The controller will auto scroll to the
first active fault.
3. To exit the menu, press ESC. Keep on pressing if the displayed parameter is not the first item of the menu.
4. The main menu is not circular; when the bottom is reached, press ESC or < to go back. The ENTER button can be used to go forward through the menu.

EG 038
The following table lists the EMV controller faults which may be reported on the DS2000XP panel display.
Table 4 – Controller LCD “fault detection” menu display
LCD “Fault Detection” item Description Action
IGBT FAULT U PHASE/HS
a. Remove high power and allow drive voltage to dissipate.
IGBT FAULT V PHASE/HS Measure voltage at the drive input for safe working voltages
before proceeding
IGBT FAULT W PHASE/HS Detects the excess current or short circuit condition of the output b. Verify system is shielded and grounded properly
IGBT three‐phase bridge or the recovery circuit IGBT. This can be
generated by noise from an improperly shielded system or a c. Check drive outputs(U2, V2, W2) with and ohmmeter for short
IGBT FAULT U PHASE/LS circuit from each output phase to all other output phases
shorted IGBT on the drive power stage.
d. Check drive outputs for phase to chassis ground short circuits.
IGBT FAULT V PHASE/LS e. If fault is permanent and the shorts are measured replace the
drive.
IGBT FAULT W PHASE/LS
It detects the excess current or short circuit condition of the
IGBT FAULT RECOVERY recovery circuit IGBT.
Detects the BUS overvoltage condition; the drive cuts off the
current. This can be due to a recovery resistance interruption or
BUS OVERVOLTAGE the resistance value is too high for the application and it cannot
dissipate the energy recovered by the motor and the drive. a. Check 144VDC bus supply voltage meets the specification.
Detects the BUS under‐voltage condition; the drive cuts off the b. Verify the drive configuration parameters “motor bus voltage
current. This can be due to a power line interruption or to an (drv.mtrbus)” = 110.
BUS UNDERVOLTAGE excessive current absorption by the drive with respect to the c. Verify there is no Connection to Recovery Resistor on the Drive.
resistance. d. Check for faulty 24V‐>144VDC supply.
Detects the DC BUS variation at DRIVE ON when the supplied e. Check for an Actuator drawing too much current.
UNSTABLE BUS AT DRIVE ON power is low (reduced or null speed). This could be due to a fuse f. Possible Faulty Drive; Replace the Drive.
interruption on the three‐phase line.
Detects the lack of DC BUS or a value lower than 80 V (minimum
NO BUS default factory set value).
a. Check 144VDC bus supply voltage meets the specifications.
b. Verify the drive configuration parameters “motor bus voltage
BUS/MOT.VOLTAGE Detects the wrong setting of motor voltage rating with respect to (drv.mtrbus)” = 110
UNCOMPATIBLE the voltage detected on DCBUS.
c. Check drive bus reading “dsp measured bus voltage (dpr.vbus)”

EG 038

Indicates the wrong value used for the recovery resistor in
connection to the line voltage. A wrong Ohm‐value (lower than the a. Verify parameters rgn_g_powext=250, rgn_g.resext = 33.
RES.REC./MAIN recommended one) causes a recovery IGBT damage due to over‐
UNCOMPATIBLE b. Verify there is no connection at terminal RR.
current. Attention: A value higher than the recommended one can c. Possible Faulty Drive; Replace the Drive
prevent braking in max supplied current condition at max speed.
SYSTEM ERROR ON VBUS It indicates an anomaly inside the voltage reading system on DC a. Try to switch the drive off and cut off the line.
DETECT BUS
b. In case the FAULT persists the drive is broken.
FLASH‐ERROR DEFAULT Indicates an error in the internal reading of the parameters in the Parameters” from the “Utility Menu” and reload configuration.

SETTING drive.
a. Verify the drive fan is working if the drive fan exists.
Indicates the drive heat‐sink over‐temperature. This can be caused b. Check current draw of actuator for abnormally high current
HEATSINK FAULT by the drive operating with current higher than the drive can levels. If levels are high replace the actuator.
supply. This may also be an indication of improper drive cooling. c. Turn off drive and let cool, If fault appears after cooling replace
the drive.
This fault is disabled in the DSP
MOTOR FAULT
OVERTEMPERATURE Indicates the motor over‐temperature. Check the application size, during the cycle an effective current higher
Indicates that the max speed set inside the drive has been This fault is disabled in the DSP
OVERCOME MAX. SPEED exceeded more than 12%.

An ENCODER is not used in this application. All the R‐R EMVs use a
RESOLVER.
UVW ENCODER DETECTION Indicates the presence of errors on the connection signals inside . Verify on the GUI Drive Configuration Screen that the

ERROR the encoder section. Position/Speed Fdbck Source is Resolver
b. Verify parameter “drv.posfbsrc = 2”

EG 038
ENCODER PULSES DETECTION
ERROR

Indicates the presence of errors on the connection signals inside c. Check Resolver Supply Voltage 20VPP @ 10KHZ with no load. If
FAULT RESOLVER the resolver section.
incorrect voltage replace drive.
actuator.
a. Check 144VDC bus supply voltage meets the specification.
+15 SUPPLY FAULT Indicates that the +15 V internal power value is out of tolerance. b. Verify the J2B pin 1 on the control head has no connection and is
not under load
check for abnormally high loads. If spikes occur in parallel with
15 volt supply fault check actuator condition
‐15 SUPPLY FAULT Indicates that the ‐15 V internal power value is out of tolerance. d. Check for excessive ambient heat
Indicates a control cards exchange between two different size b. Verify the correct drive model number is used
FAULT SIZE drives.
c. If still exists download parameters, and perform a “Save

EG 038

FLASH ERROR CHECKSUM Indicates an internal memory error. Parameters” from the “Utility Menu”
Indicates that the IGBT protection begin active for excessive phase This fault should be disabled in the Drive.
IGBT FAULT I2T PROTECTION current at locked rotor or very low speed condition.
a. Verify parameters:‐ igbt.fltena =0, igbt.run = 0.
a. Verify parameters:‐
Indicates an excessive estimated temperature of the recovery rgn_g_powext=250, rgn_g.resext = 33.
FAULT RR PROTECTION
resistor. b. Verify there is no connection at terminal RR.
c. Possible Faulty Drive; Replace the Drive
END OF SCANNING Press ENTER for exit

EG 038
5.4 Motor controller, GUI information
If a PC is available that has had the Moog controller GUI application software loaded then it can be connected to the RS232 port on the controller (using a suitable communications
cable). With the GUI available, the controller configuration and fault status can be interrogated directly from the controller. The GUI provides access to similar lists of controller
parameters and fault conditions as the controller’s fascia panel LCD display but provides more comprehensive coverage. For this reason the same faults appear in both Table 4 and
Table 5 and the recommended service action will be similar.
The GUI should only be used if other fault‐diagnostics are unable to trace a problem with the motor controller.
Table 5 – Controller GUI display: MCC faults
GUI – “MCC Fault” item Description Action
a. Verify on the Drive Configuration Screen that the model is
DYNAMIC POS. FOLLOWING Indicates while the actuator is in motion it has exceeded the enabled
ERROR dynamic position error limit. This limit is settable via the Combined b. Verify parameter Set (mdlrun = 1, drv.dynposwin = N/A)
Tuning screen parameter set.
c. This fault is not used while the model is running
a. Verify on the Drive Configuration Screen that the model is
STATIC POS FOLLOWING Indicates while the actuator is stationary it has exceeded the static enabled
ERROR position error limit. This limit is settable via the Combined Tuning b. Verify parameter Set (mdlrun = 1, drv.staposwin = N/A)
screen parameter set.
c. This fault is not used while the model is running

EG 038

a. Verify the CAN cable connection
b. Power cycle the drive and the Host connection
c. Verify parameters model execution rate(mdlrte) = 2 if using
FIELDBUS COMMS ERROR Indicates the Fieldbus(Can bus) is not responding device net, or model execution rate(mdlrte) = 1 if using analog
d. Verify “Controller Sample Period” = 0.00025 for an analog system,
and Controller Sample Period = 0.0005 for a device net system.
e. Replace Drive
a. Verify the host command algorithm.
b. Verify parameters model execution rate(mdlrte) = 2 if using
device net, or model execution rate(mdlrte) = 1 if using analog
COMMAND BUFFER FULL Drive is receiving more commands on the Fieldbus than can be
processed causing Buffer overrun c. Verify “Controller Sample Period” = 0.00025 for an analog system,
and Controller Sample Period= 0.0005 for a device net system.
d. Verify on the Combined Tuning screen that
Reference Source = Bus.
a. Verify the CAN cable
b. Verify the host command algorithm.
c. Verify parameters model execution rate(mdlrte) = 2 if using
d. Verify “Controller Sample Period” = 0.00025 for an analog system,
Occurs when the Reference source has no command. If the and Controller Sample Period= 0.0005 for a device net system.
COMMAND BUFFER EMPTY Reference Source is configured for BUS but no command is received e. Verify on the Combined Tuning screen that
over the Fieldbus this fault will occur. Reference Source = Bus.

INTERPOLATION FAULT This fault is not used

EG 038

a. Check Parameters on Combined Tuning, Drive Configuration
screens and verify the Controller Parameter Database.
PARAMETERS INVALID Certain Configuration Parameters are out of range. Lower limit
upper limit
Actual setting

PLL TIMEOUT Phase Lock Loop cannot lock into fieldbus time synchronization. Only used in Serco Fieldbus communications.
a. Cycle drive power
MODEL ERROR Drive Model code is corrupt b. Perform a File‐>EEPROM save‐>Model Save and click Write
Parameters and cycle power.
c. Replace drive
The EMVs use a RESOLVER not an ENCODER
UNKNOWN ENCODER The encoder connected to the DS2000XP was not recognised as a
supported type a. Verify on the GUI Drive Configuration Screen that Position/Speed
Fdbck Source is set to Resolver

EG 038
ENCODER CHECKSUM ERROR The EEPROM onboard the encoder has an invalid checksum
ENCODER SERIAL TIMEOUT An error was detected on the Sin/cosine line of the encoder
ENCODER CALIBRATION The position calibration of the encoder failed
FAULT

b. An encoder is not used in this application Verify parameter
“drv.posfbsrc = 2”
FAULT RESOLVER Indicates the presence of errors on the connection signals inside the c. Check Resolver Supply Voltage 20VPP @ 10KHZ with no load. If
resolver section incorrect voltage replace drive.
actuator.
+15 SUPPLY FAULT Indicates that the +15 V internal power value is out of tolerance. b. Verify the J2B pin 1 on the control head has no connection and is
not under load
check for abnormally high loads. If spikes occur in parallel with
15 volt supply fault check actuator condition
‐15 SUPPLY FAULT Indicates that the ‐15 V internal power value is out of tolerance. d. Check for excessive ambient heat

EG 038

FAULT SIZE Indicates a control cards exchange between two different size b. Verify the correct drive model number is used
drives. c. If still exists download parameters, and perform a “Save
Indicates an internal memory error. b. If still exists download parameters, and perform a “Save
FLASH ERROR CHECKSUM Parameters” from the “Utility Menu”
a. Verify parameters rgn_g_powext=250, rgn_g.resext = 33.
Indicates an excessive estimated temperature of the recovery
FAULT RR PROTECTION resistor. b. Verify there is no connection at terminal RR.
a. Measure the DC Supply and look for variations in the 144VDC
SYSTEM ERROR ON VBUS supply voltage.
Indicates an anomaly inside the voltage reading system on DC BUS.
DETECT b. Switch the drive off and cut off the line. If the FAULT persists, the
drive is broken.
INVALID DRIVE SIZE The stored value of the Drive Size and the actual Size of the Power b. Verify the correct drive model number is used
Stage are different. c. If still exists download parameters, and perform a “Save

EG 038

Perform a File‐>EEPROM save‐>Factory Save and click Write
Parameters.
FACTORY CONFIG INVALID Factory Parameters are not configured properly.

EG 038

a. Verify parameters model execution rate(mdlrte) = 2 if using
b. Verify “Controller Sample Period” = 0.00025 for an analog system,
and Controller Sample Period= 0.0005 for a device net system.
The model could not execute in the allotted time. The drive
MODEL OVERRUN ERROR parameter set must be set so the model has sufficient time to
execute it’s commands.

a. Verify Overcurrent timeout on the Drive Configuration Screen is
properly set for the application: “I2T time”= 0.5.
I2T FAULT The I2T(current limiting) time has expired.
b. Verify Parameter igbt.fltena = 0
c. Verify the motor/actuator is not jammed.
REGEN EXCEED FAULT Continuous regen power has been exceeded. b. Verify there is no connection at terminal RR.
REGEN CONFIGUATION FAULT The selected Regen resisitor is wrong for the drive size and supply b. Verify there is no connection at terminal RR.
voltage.
INCOMP BOARD FIRMWARE Hardware control card version (Can bus/Firewire/Sercos) does not Replace drive
match the firmware.

EG 038

The EMVs use a RESOLVER not an ENCODER
a. Verify on the GUI Drive Configuration Screen that Position/Speed
Fdbck Source is set to RESOLVER
Hyperface Encoder position has been modified. Auto Phasing
ENCODER POSITION CHANGED should be repeated.

b. An encoder is not used: Verify parameter “drv.posfbsrc = 2”

EG 038

a. Verify parameter Set (mdlrun = 1, drv.velwin = N/A)
b. This fault is not used while the model is running
VELOCITY ERROR FAULT Velocity error has exceeded the programmed window and time. See
settings on the Combined Tuning Screen.

a. Check for sticking actuator
PHASE U OVERCURRENT Overcurrent detect on Phase U
b. Faulty drive
a. Check for sticking actuator
PHASE V OVERCURRENT Overcurrent detect on phase V.
b. Faulty drive
a. Cycle power
SOFTWARE ERROR Internal Software Error has occurred. b. Reload configuration & power cycle
c. Replace drive

EG 038

a. Perform a File‐>EEPROM save‐>Model Save and click “Write
Parameters” and cycle power.
b. If the problem persists the EEPROM might be damaged so replace
the drive.
MODEL PARAMETERS INVALID Occur Model parameters are invalid or corrupted.

SOFTWARE WATCHDOG The internal software watchdog expired. Verify the sample period on the Drive Configuration Screen
TIMEOUT

EG 038

Table 6 – Controller GUI Display, DSP Faults
GUI – “DSP Fault” item Description Action
b. Verify the drive configuration parameters “motor bus voltage
Detects the BUS overvoltage condition; the drive cuts off the (drv.mtrbus)” = 110.
BUS OVERVOLTAGE current. This can be due to a recovery resistance interruption or the c. Verify there is no Connection to Recovery Resistor on the Drive
resistance value is too high for the application and it cannot
dissipate the energy recovered by the motor and the drive. d. Check for faulty 24V‐>144VDC supply
e. Check for an actuator drawing too much current
f. Possible Faulty Drive; Replace the Drive
Detects the BUS under‐voltage condition; the drive cuts off the
BUS UNDERVOLTAGE current. This can be due to a power line interruption or to an
excessive current absorption by the drive with respect to the
resistance.
The detected voltage on the DC bus fluctuates too much.
RATE OF CHAN. BUS VOLTAGE Detects the DC BUS variation at DRIVE ON when the supplied power Verify fuses on the three phase input line.
is low (reduced or null speed). This could be due to a fuse
interruption on the three‐phase line.
The Motor Voltage parameter (rated bus voltage of the motor)
value and the power stage max bus voltage are incompatible.
INCOMPATIBLE BUS & MOTOR
Detects the wrong setting of motor voltage rating with respect to
the voltage detected on DCBUS.
The detected DC Bus is below 70 Volt.
NO BUS Detects the lack of DC BUS or a value lower than 80 V (minimum
default factory set value).
BUS READ The drive cannot read the DC bus properly. Cycle power. If the fault persists the drive is damaged.
The internal temperature in the drive is too high. If the drive is a. Verify that cooling fans are operating properly if the drive fans
improperly sized for the application the drive must absorb too exists.
much current during the cycle. b. Check current draw of actuator for abnormally high current
HEATSINK TEMPERATURE
Indicates the drive heat‐sink over‐temperature. This can be caused levels. If levels are high replace the actuator.
by the drive operating with current higher than the drive can c. Turn off drive and let cool, If fault appears after cooling replace
supply. This may also be an indication of improper drive cooling. the drive.
U PHASE HIGH SIDE IGBT Excess current or a short circuit condition detected on the high side a. Remove high power and allow drive voltage to dissipate.
or low side leg of an IGBT output stage or the recovery circuit IGBT. Measure voltage at the drive input for safe working voltages
V PHASE HIGH SIDE IGBT This can be generated by noise from an improperly shielded system before proceeding
W PHASE HIGH SIDE IGBT or a shorted IGBT on the drive power stage. b. Verify system is shielded and grounded properly

EG 038
GUI – “DSP Fault” item Description Action

U PHASE LOW SIDE IGBT c. Check drive outputs(U2, V2, W2) with an ohmmeter for short
circuit from each output phase to all other output phases
V PHASE LOW SIDE IGBT d. Check drive outputs for phase to chassis ground short circuits.
W PHASE LOW SIDE IGBT e. If fault is permanent and the shorts are measured replace the
drive.
a. Cycle Power.
FLASH READ The EEPROM cannot be read during power up. b. If problem persists, do a Save Parameters on the front panel of
the DS2000XP.
c. If problem persist the EEPROM is damaged.
FEEDBACK RESOLUTION The configured Feedback Resolution is invalid. Check Hiperface Parameters screen and verify Encoder Feedback
Resolution value.
+15V RAIL ERROR The internal +15Vdc is out of tolerance.
+15V RAIL ERROR The internal ‐15Vdc is out of tolerance.
POWER SIZE MISMATCH The stored value of the Drive Size and the actual size of the Power Perform a Save Parameters on the front panel of the DS2000XP.
Stage are different.
This fault is disabled in DSP
MOTOR TEMPERATURE FAULT The Motor NTC/PTC over temperature threshold was exceeded. Check the application size, during the cycle an effective current higher
This fault is disabled in DSP
MOTOR OVERSPEED The Max. Motor Speed value was exceeded by more than 10
percent. Check that the speed loop is properly calibrated and that the motor
braking torque is sufficient with respect to the connected load.
a. Cycle power.
FLASH CHECKSUM ERROR The EEPROM of the DSP card has a checksum error. b. If problem persists perform a Save Parameters from the front
panel of the DS2000XP.
c. If problem still persists the EEPROM is damaged.
RESOLVER FAULT An error was detected on the resolver. Check signal wires for proper connections.
DS2000XP CARD FAULT This fault is set when any DSP or MCC fault is active. It will
automatically clear when no errors are present.

EG 038

EG 038

EG 038

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Energy Guide

© Rolls-Royce Power Engineering plc (2012)

Rev. Date Author

Symptom Possible Fault / Explanation Suggested Action

Symptom Possible Fault / Explanation Suggested Action

Symptom Possible Fault / Explanation Suggested Action

(c) Measure the resistance between terminals U and W (Black), terminals U and V (b) If visual position indicator moves normally, proceed to actions A11 and A12. If

Unit HMI Controller Fault Description Action

Unit HMI Controller Fault Description Action

LCD “Fault Detection” item Description Action

LCD “Fault Detection” item Description Action

LCD “Fault Detection” item Description Action

GUI – “MCC Fault” item Description Action

GUI – “MCC Fault” item Description Action

PARAMETERS INVALID Certain Configuration Parameters are out of range. Lower limit

GUI – “MCC Fault” item Description Action

GUI – “MCC Fault” item Description Action

GUI – “MCC Fault” item Description Action

GUI – “MCC Fault” item Description Action

GUI – “MCC Fault” item Description Action

GUI – “MCC Fault” item Description Action

GUI – “MCC Fault” item Description Action

GUI – “DSP Fault” item Description Action

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