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Related Manuals for Hamilton Sundstrand Company Gas Fuel Metering Valve HFG2.0
Summary of Contents for Hamilton Sundstrand Company Gas Fuel Metering Valve HFG2.0
- Page 1 User Manual HFG2.0 Gas Fuel Metering Valve SD-6009 Rev. 6 August 2008 PRECISION ENGINE CONTROLS CORPORATION...
- Page 2 This manual provides installation, maintenance, and operating instructions for the HFG2.0 Gas Fuel Metering Valve. Every attempt has been made to provide sufficient information in this manual for the proper operation and preventive maintenance of the valve. Read this manual in its entirety to fully understand the system.
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Page 3: Table Of Contents
TABLE OF CONTENTS Purpose of This Guide ... iii Product Identification... iii What the User Should Know ... iv Related Publications... iv INSTALLING THE HFG2.0 ... 1 1.1 Before Beginning... 1 1.2 General Specification Summary... 3 1.3 Mechanical Installation... 4 1.4 Electrical Connections... - Page 4 Figure 1-11. Typical Power Connection With Battery...15 Figure 1-12: HFG2.0 System Signal Wiring Diagram...19 Figure 1-13. Typical Analog Input Connection...20 Figure 1-14. Typical Analog Output Connection...20 Figure 1-15. Typical Discrete Input Command Connection ...20 Figure 1-16. Typical Discrete Output Alarm Connections ...21 Figure 1-17.
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Page 5: Purpose Of This Guide
Purpose of This Guide This publication is designed to help the user install, operate, maintain and troubleshoot the HFG2.0 Gas Fuel Metering Valve. Product Identification Most of the information in this manual is applicable to all generations of the product. Where unique information applies to a specific generation, one of the following symbols will be shown to indicate as such: Fourth generation (isolated RS-232) P/Ns: 5002605-XXX, 5002610-XXX, 5002447-XXX or:... -
Page 6: What The User Should Know
What the User Should Know To install, operate and troubleshoot the HFG2.0, it is necessary for the user to have a fundamental understanding of: • • Related Publications • Electronics concepts, such as voltage, current, and switches Mechanical motion control concepts, such as inertia, torque, velocity, distance, force ActWiz Software Operations Manual (p/n SD-6010) HFG2.0 USER GUIDE... -
Page 7: Installing The Hfg2.0
1 INSTALLING THE HFG2.0 1.1 Before Beginning Inspection The HFG2.0 should be inspected immediately after unpacking. Check for dings or dents or any other obvious signs of damage. Remove the protective caps from the connectors and check for any bent pins or damage to the threads of the connectors. -
Page 8: Electrical Noise Guidelines
Electrical Noise Guidelines PECC has taken the following measures to reduce electrical noise with the HFG2.0: • An additional measure to reduce electrical noise is to: • Environmental Considerations The HFG2.0 operates satisfactorily with ambient air temperature of -40 °C (-40 °F) to +93 °C (+200 °F), and is designed as an explosion-proof assembly. -
Page 9: General Specification Summary
1.2 General Specification Summary PARAMETER Power Input Voltage Range Maximum Current Typical Transient Current Typical Continuous Current Inputs and Outputs Discrete Inputs RUN and RESET commands Discrete Outputs FAULT & OVERTEMP alarms Analog Input DEMAND command signal Analog Outputs POSITION & MTR CURRENT feedback Maximum Common Mode Voltage Performance Maximum Operating Pressure... -
Page 10: Mechanical Installation
Certifications North American Certifications European Directive Compliance (CE Mark) Materials Actuator Housing Valve Housing Conduit Union Seals Connectors Dimensions Weight 1.3 Mechanical Installation This section describes proper HFG2.0 installation. Ensure compliance with the factory recommendations. Typical Fuel System The HFG2.0 installs as part of a gas fuel system as shown in Figure 1-1. In this arrangement, the HFG2.0 is located downstream from two normally closed gas shut-off valves. -
Page 11: Figure 1-1. Typical Hfg2.0 Gas Fuel System Installation
Figure 1-1. Typical HFG2.0 Gas Fuel System Installation Figure 1-2. Alternate HFG2.0 Gas Fuel System Installation Dimensions Figure 1-3 and Figure 1-4 show external dimensions for the 3-piece housing and 1-piece housing versions of the HFG2.0, respectively. Mounting Considerations The HFG2.0 can be mounted directly to a gas turbine engine skid using brackets provided by the engine manufacturer. - Page 12 The HFG2.0 includes four (4) 0.50-24 UNC-2B mounting holes with stainless steel heli-coil inserts for securing the valve body. The mounting holes on the standard version of the HFG2.0 are located on the opposite side from the electrical connectors. The mounting holes on the reversed version of the HFG2.0 are located on the same side as the electrical connectors (see Figure 1-5).
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Page 13: Pipe Connections
Explosion Hazard – Do not remove the clevis. Removing the clevis violates the warranty. Care should also be taken when rotating the clevis or indexing the screw pattern to avoid scratching the flame path or introducing particulates to the assembly. Pipe Connections The standard pipe connection for the HFG2.0 is per SAE J518, -32 (2 inch), code 61. -
Page 14: Figure 1-3. Hfg2.0 Dimensions, 3-Piece Housing
Vent Port The gas leakage rate through the vent port is less than 200 cm /hr (air or as test flow). The vent port features a 1/8-NPT fitting. See Figure 1-4. Consult local installation codes to determine whether and how to connect this port. -
Page 15: Figure 1-4. Hfg2.0 Dimensions, 1-Piece Housing
Figure 1-4. HFG2.0 Dimensions, 1-Piece Housing INSTALLING THE HFG2.0... -
Page 16: Figure 1-5. Hfg2.0 Mounting Orientations
Figure 1-5. HFG2.0 Mounting Orientations HFG2.0 USER GUIDE... -
Page 17: Figure 1-6. Hfg2.0 Mounting Provisions, 3-Piece Housing (Standard Mounting)
Figure 1-6. HFG2.0 Mounting Provisions, 3-Piece Housing (Standard Mounting Orientation Shown) INSTALLING THE HFG2.0... -
Page 18: Figure 1-7. Hfg2.0 Mounting Provisions, 1-Piece Housing (Standard Mounting)
Figure 1-7. HFG2.0 Mounting Provisions, 1-Piece Housing (Standard Mounting Orientation Shown) HFG2.0 USER GUIDE... -
Page 19: Figure 1-8. Hfg2.0 Mounting Provisions, 1-Piece Housing (Reversed Mounting)
Figure 1-8. HFG2.0 Mounting Provisions, 1-Piece Housing (Reversed Mounting Orientation Shown) INSTALLING THE HFG2.0... -
Page 20: Electrical Connections
1.4 Electrical Connections The HFG2.0 is suitable for use in hazardous locations. See the General Specification Summary in Section 1.2 for certifications. Ensure compliance with the factory recommendations, and that wiring is in accordance with local requirements. WARNING: 94/9/EC (ATEX) Compliance – Special Conditions for Safe Use: Two special factory-sealed unions are mounted on the equipment to ensure the electrical connection to the network and to provide the feedback signal to the user. -
Page 21: Figure 1-9: Hfg2.0 System Power Wiring Diagram
Figure 1-9: HFG2.0 System Power Wiring Diagram Figure 1-10. Typical Power Connection With Power Supply Figure 1-11. Typical Power Connection With Battery WARNING - Shock Hazard Connect both the 120 VDC power and auxiliary wires. If only the primary power wires are connected, the 120 VDC auxiliary power wires are electrically live and must be insulated on the ends. -
Page 22: Table 1-2. Power Supply Requirements
Power Supply Requirements Table 1-2 below lists the power supply requirements for the HFG2.0. Voltage Max. Ripple Current *Output Capacitance Table 1-2. Power Supply Requirements *The output capacitance applies for non-battery power systems and assumes full-stroke step changes in actuator position at rated load. This value is typical. The actual value required is dependent on the user’s specific DC power system design, including: •... -
Page 23: Table 1-3. Wire Size For Hfg2.0 Power Harness
Therefore, it is not possible to correctly state a single capacitance value that should be placed on the bus. It may require no added bus capacitance or hundreds of thousands of microfarads of capacitance. A typical output capacitance value used for non-battery power systems is 50,000uF, but the actual value depends on the specific power system as discussed above. -
Page 24: Signal Connections
Signal Connections Signals are sent between the HFG2.0 and the user’s controller through the integral 17-wire signal harness. See Table 1-4 for the wire list for this harness. See Figure 1-12 for the system signal wiring diagram. WHITE/ORANGE/YELLOW WHITE/ORANGE/BLUE WHITE/ORANGE/GREEN BLACK WHITE/BLACK ORANGE... -
Page 25: Figure 1-12: Hfg2.0 System Signal Wiring Diagram
Figure 1-12: HFG2.0 System Signal Wiring Diagram Note: For proper operation of the controller, the voltage between the control inputs and the negative terminal of the power supply should be below 200 VDC. Note: The Serial Return is internally connected to the 120 VDC input Return. -
Page 26: Figure 1-13. Typical Analog Input Connection
Analog Inputs The analog input, DEMAND, has a current range of 4 - 20 mA. It is electrically isolated up to 500 VAC from the enclosure, 120 VDC power, digital I/O, and serial interface. The analog interfaces are not isolated from each other. -
Page 27: Discrete Outputs
Discrete Outputs The discrete outputs are +24 VDC. They are electrically isolated up to 500 VAC. See Figure 1-16 for a typical discrete output alarm connection. CONTROLLER DISCR ETE INPUT FAULT ALARM OVERTEMP ALARM FAULT RTN OVERTEMP RTN CONTROLLER DISCRETE INPUT FAULT RTN OVERTEMP ALARM RTN [WHT/BLK] FAULT ALARM... -
Page 28: Table 1-5. Computer Com Port Pin Outs
Table 1-5. Computer COM Port Pin Outs Property Damage Hazard – The serial inputs are not electrically isolated could result in actuator or computer damage. Use separate conduits for power and signal wiring. Close proximity to power lines may cause signal interference. Shock Hazard –... -
Page 29: Table 1-6. Wire Size For Hfg2.0 Signal Harness
Recommended Wiring for System Signals The recommended wiring is a 17-conductor shielded cable containing twisted-pair wires with individual shields. Use a wire size large enough to accommodate the installation and provide a maximum fifty (50) ohm loop resistance. See Table 1-6 for recommended wire sizes. DISTANCE TO USER’S CONTROLLER ≤... - Page 30 NTENTIONALLY LANK HFG2.0 USER GUIDE...
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Page 31: Understanding The Hfg2.0
2 UNDERSTANDING THE HFG2.0 2.1 System Description The HFG2.0 is an electrically operated gas fuel-metering valve that requires only 120 VDC power, an analog fuel demand signal, and a discrete RUN command to achieve basic operational capability. No pneumatic or hydraulic power is required. The HFG2.0 is a closed loop servo system containing Motor Control Electronics (MCE), a brushless DC-motor-driven ball screw actuator and valve flow body assembly. -
Page 32: Electrical Description
2.2 Electrical Description The electric actuator in the HFG2.0 incorporates digital motor control electronics (MCE). The MCE contain analog to digital converters, a digital signal processor (DSP), application specific integrated circuit (ASIC) and power supplies. Figure 2-1 shows the system block diagram. The MCE provides the interface for the user’s engine control system and power supply. - Page 33 during the RESET command. To reset the HFG2.0, +24 VDC must be applied across the RESET wires for at least 0.5 seconds in order to reset the controller and actuator. DEMAND Signal The DEMAND signal is a user-provided analog input that is used to control the position of the valve.
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Page 34: Figure 2-1. Hfg2.0 Electronics System Block Diagram
Figure 2-1. HFG2.0 Electronics System Block Diagram HFG2.0 USER GUIDE... - Page 35 Alarms The HFG2.0 provides two two-wire alarm signals via the integral 17-wire signal harness. The discrete alarm outputs are solid-state switches which are normally closed. The user’s controller provides +24 VDC to complete the circuit. Refer to Figure 1-16 for typical connections. Refer to the General Specification Summary Table in Section 1.2 for alarm specification values.
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Page 36: Mechanical Description
2.3 Mechanical Description The HFG2.0 consists of two main parts, an actuator and a valve assembly. Actuator The actuator is the primary drive mechanism for the valve assembly. The actuator portion of the HFG2.0 consists of four main assemblies: • •... - Page 37 monitor winding temperatures. The motor electrical power and thermistor wires pass through a conduit into the electronics housing. Motor Rotor The motor rotor is locked to the ball screw shaft via a straight key. The motor rotor contains powerful magnets that align with the energized stator windings, thereby creating torque and shaft rotation.
- Page 38 Extension Rod and Bearings The extension rod is threaded on the ball nut. As the ball nut translates, the extension rod moves in and out of the HFG2.0 main housing. Counter-clockwise (CCW) rotation (facing the motor end of the actuator) of the motor rotor and screw shaft results in the extension rod extending out of the main housing.
- Page 39 Orifice Assembly The orifice assembly contains a set of poppets and orifice plates. Fuel flow is metered between the INLET port chamber and OUTLET port chamber in proportion to the poppet position and resultant flow area. The poppet assembly is connected to the extension rod of the actuator. As the actuator retracts, the poppet assembly retracts to increase the flow area between the poppets and the two orifices.
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Page 40: Figure 2-2. Hfg2.0 Cut-Away View - Actuator Main Housing Assembly
Figure 2-2. HFG2.0 Cut-Away View – Actuator Main Housing Assembly HFG2.0 USER GUIDE... -
Page 41: Figure 2-3. Hfg2.0 Cut-Away View (Partial)
Figure 2-3. HFG2.0 Cut-Away View (Partial) CH. 2: UNDERSTANDING THE HFG2.0... -
Page 42: Identification Plate
2.4 Identification Plate Figure 2-4. Typical Identification Plate A product identification plate is attached to the HFG2.0 housing assembly. Figure 2-4 shows a typical identification plate. The identification plate lists model designation, product part number, revision and unit serial number. Hazardous area operation, certification and electrical wiring interface information is also provided. -
Page 43: Figure 2-5. Typical Refurbishment Plate
Figure 2-5. Typical Refurbishment Plate CH. 2: UNDERSTANDING THE HFG2.0... - Page 44 NTENTIONALLY LANK HFG2.0 USER GUIDE...
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Page 45: Operating The Hfg2.0
3 OPERATING THE HFG2.0 This section refers to the position of the actuator when describing operation of the HFG2.0 valve. The end of the actuator extension rod is connected to the poppet assembly of the valve. The linear motion of the actuator, both extension and retraction, is directly translated to the poppet assembly. -
Page 46: Holding Motor Current State
this point, the HFG2.0 has no information about the position of the actuator extension shaft. When the HFG2.0 receives the RUN command, it will initiate motion in the homing direction. The default homing direction for the HFG2.0 is “Extend”. This means that the first movement after Power Up or Reset will be an extension of the actuator in the HFG2.0. -
Page 47: Figure 3-1. Hfg2.0 Basic Operation Flow Chart
Figure 3-1. HFG2.0 Basic Operation Flow Chart CH. 3: OPERATING THE HFG2.0... -
Page 48: Moving To Stop Position
3.4 Moving to Stop Position The Stop position is a fail-safe position that may be set anywhere between Home (zero position, Valve Closed) and maximum span (maximum flow). The default value for Stop position is 0.0 inches, as defined in the Set-Up parameters. The actuator will move to the Stop position if the DEMAND signal is ≤... -
Page 49: Figure 3-2. Hfg2.0 Actuator Position Vs. Demand
Full Span Position (Maximum Flow) The Full Span (Maximum Flow) position correlates to a DEMAND signal of 20 mA. The maximum Span possible for the HFG2.0 is 1.0 inches due to the configuration of the valve assembly. The maximum Span possible for the actuator used in the HFG2.0 is 2.0 inches due to its mechanical configuration. -
Page 50: Resetting The Actuator
A non-linear interpolation table can be created to define positioning at 16 discrete current levels in the DEMAND signal range, but only during Set Up using the ActWiz Software. See the Section 3.8 for additional details about Set Up parameters. Figure 3-3. -
Page 51: Monitoring System Health
3.7 Monitoring System Health The firmware program continuously monitors system health while the HFG2.0 is powered. If any of the health parameters are out of the normal operating range, the MCE outputs a discrete fault alarm to the user’s controller. Some fault causes are: •... - Page 52 See Table 3-4 for a list of Over Temp conditions represented by the OVERTEMP alarm in earlier generations of the HFG. Fault File The HFG2.0 firmware also captures the fault data in the EEPROM. If the HFG2.0 is operational, a fault file can be downloaded using ActWiz software via the RS232 interface.
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Page 53: Table 3-1. Default Configuration For Fault Alarm
Fault Type Alarm Driver Overcurrent Tracking Error Position Demand 3.5 mA RDC Failure +14 Volts 12.0 Volts –14 Volts –16.0 Volts Input Voltage 75.0 Volts EEPROM Checksum Motor High Temp Electronics High Temp +5 Volts 4.5 Volts Watchdog Expired EEPROM Write Table 3-1. -
Page 54: Table 3-3. Fault Configuration For Fault Alarm
Fault Alarm Type Driver Over Current Tracking Error Watchdog Expired Retract/Extended Unregulated Voltage Low +14 Volts Low +14 Volts High -14 Volts High Input Voltage Low Input Voltage High Electronics Over Temp Table 3-3. Fault Configuration For FAULT Alarm Persist Time 10 Sec 1 Sec 10 Sec... -
Page 55: Fault Type
Fault Type Persist Time Motor 10 Sec 1 Sec Electronics 10 Sec 1 Sec Table 3-4. Fault Configuration For OVERTEMP Alarm Automatic Shutdown Feature The HFG2.0 has a self-protective shutdown feature. The HFG2.0 will shutdown if: • Any two motor winding temperatures exceed 135 °C for ten (10) seconds •... -
Page 56: Changing Set-Up Parameters
3.8 Changing Set-Up Parameters The HFG2.0 uses a number of variables to define its functionality. These variables are called Set-Up parameters and they are stored in the EEPROM in the HFG2.0. Default values for these variables are loaded into the EEPROM at the PECC factory. The Set-Up parameters are reloaded into the system registers each time the HFG2.0 is powered up or reset. -
Page 57: Table 3-5. Typical Hfg2.0 Setup Parameters With Default Values
PARAMETER Part Number Describes part number of actuator model Actuator Type Describes type of actuator Command Source Sets type of command signal Home Controls the direction the actuator will move, extending or retracting, to find the mechanical stop (HOME) Span Sets the maximum stroke length, measured from the HOME position Stop Position... - Page 58 NTENTIONALLY LANK HFG2.0 USER GUIDE...
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Page 59: Maintaining The Hfg2.0
4 MAINTAINING THE HFG2.0 Under normal operation, the HFG2.0 requires no formal maintenance program. Regularly scheduled inspections should be performed to check for: • • • • • • 4.1 Refurbishment PECC recommends that the HFG2.0 be shipped back to the factory for refurbishment when the user’s system is shut down for overhaul (typically after approximately 30,000 hours of operation.) Contact PECC for details about refurbishment. - Page 60 NTENTIONALLY LANK HFG2.0 USER GUIDE...
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Page 61: Troubleshooting
5 TROUBLESHOOTING This section provides troubleshooting information for the HFG2.0. You can isolate most electrical faults by using an external oscilloscope and digital voltmeter (DVM) and computer with diagnostic software. The HFG2.0 is comprised of highly reliable components and should not develop service problems under normal operating conditions. - Page 62 Symptom Probable Causes Valve Inoperative - Power Wires not connected FAULT alarm No or low 120 VDC power Valve Inoperative - No RUN or position command NO FAULT alarm Actuator moves toward Intermittent RUN command HOME then stops Homing Force Too Low No position demand Actuator moves toward Intermittent RESET command...
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Page 63: Table 5-1. Initial Installation Troubleshooting Chart
Symptom Probable Causes RS232 Interface Inoperative Incorrect wiring No or low 120 VDC power COM1 not connected RESET or RUN command is Table 5-1. Initial Installation Troubleshooting Chart Symptom Probable Causes No valve feedback No or low 120 VDC power Self-protective valve auto shut down FAULT alarm... -
Page 64: Table 5-3. Hfg2.0 Electrical Continuity Troubleshooting Chart
Function DEMAND RESET POWER MOTOR CURRENT POSITION FAULT Alarm OVERTEMP Alarm Table 5-3. HFG2.0 Electrical Continuity Troubleshooting Chart Actuator Wire Colors Resistance Value BRN and WHT/BRN 225Ω VIO and WHT/VIO 4.7 KΩ GRY and WHT/GRY 4.7 KΩ RED and GREEN High Impedance, but not open circuit. -
Page 65: Fault File
5.1 FAULT File The FAULT and OVERTEMP alarms are discrete outputs from the HFG2.0. The FAULT and OVERTEMP alarm circuits are closed in the normal operating condition. If the HFG2.0 detects a fault, the alarm circuit for that fault opens, and the user-provided controller should detect the open circuit. - Page 66 Watchdog expired The MCE watchdog timer continuously monitors the firmware program. Should the MCE firmware program stop functioning, or attempt to access an illegal address, the MCE signals a fault. This fault does not clear without RESET command. Resolver to Digital Converter (RDC) failure The MCE contains a resolver to digital converter chip (RDC) that provides position feedback information to the DSP.
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Page 67: Appendix A: Decommissioning & Disposal
APPENDIX A: DECOMMISSIONING & DISPOSAL This section contains recommended HFG2.0 decommissioning and disposal practices. It is for permanent removal or replacement of the installed product, with no intentions of rework, overhaul, or to be used as spares. For removal follow proper lockout /tagout procedures and verify no live electrical circuits: •... - Page 68 NTENTIONALLY LANK HFG2.0 USER GUIDE...
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Page 69: Appendix B: Glossary
APPENDIX B: GLOSSARY Term RUN Command RESET Command Controller Fuel Demand Position Demand Feedback Motor Current Feedback FAULT alarm OVERTEMP alarm HOME Homing sequence SPAN STOP position Maximum Velocity Maximum Homing Force Maximum Holding Force Definition A discrete 24 VDC signal that enables the HFG2.0 actuator and valve to move. - Page 70 NTENTIONALLY LANK HFG2.0 USER GUIDE...
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