Hamilton Sundstrand Company Gas Fuel Metering Valve HFG2.0 manual

User Manual HFG2.0 Gas Fuel Metering Valve SD-6009 Rev. 6 August 2008 PRECISION ENGINE CONTROLS CORPORATION[...]

This manual provides installation , maintenance , and operating instructio ns 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 pr eventive maintenance of the valve. Rea d this manual in its entirety to fully understand the system. Operating the HFG2.0 G[...]

T ABLE OF CONTENTS Purpose of This Guide ............................................................................................................................... .... iii Product Identification ............................................................................................................................... ....... iii What the [...]

ii HFG2.0 USER GUIDE Figure 1-11 . Typical Po wer Connection With Battery ....................................................... 15 Figure 1-12: HFG2.0 Sy stem Signal Wiri ng Diagram ...................................................... 19 Figure 1-13 . Typical Ana log Input Connec tion ............................................................[...]

Purpose of This Guide This publication is designed to help the user insta ll, operate, maintain and troubleshoot the HFG2.0 Gas Fuel Metering Valve. Product Identification Most of the information in this manua l is applicable to all generat ions of the product. Where unique inf ormation applies to a specif ic generation, one of the following symbol[...]

iv HFG2.0 USER GUIDE What the User Should Know To install, operate a nd troubleshoot th e HFG2.0, it is necessary for the user to have a fundament al understanding of: • Electronics concepts, such as voltage, current, and switches • Mechanical motion control concept s, such as inertia, torq ue, velocity, distance, force Related Publications •[...]

1 INST ALLING THE HFG2.0 1.1 Before Beginning Inspection The HFG2.0 should be inspected immediately after unpa cking. 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 t he connectors. Examine the wires of the signal and power harness[...]

2 HFG2.0 USER GUIDE Electrical Noise Guidelines PECC has taken the follow ing measures to reduce electrical noise wit h the HFG2.0: • High-voltage wires are routed separately from low-level signals through the use of separ ate power and signal harnesses. An additional measure to reduce electr ical noise is to: • Ensure that the HFG2.0 is prop e[...]

1.2 General S pecification Summary PARAMETER VALUE Power Input Voltage Range 80-160 VDC; 120 VDC nominal Maximum Current 20 A Typical Transient Current +20A < 60ms; +1 0A < 120ms; -5A < 100ms Typical Continuous Current < 1A Inputs and Outputs Discrete Inputs RUN and RESET commands ON Voltage: 12 – 32 VDC, +24 VDC nominal @ 6.5 mA OFF [...]

4 HFG2.0 USER GUIDE Certifications North American Certifications CSA Class I, Div 1, Group B, C, D; T4 European Directive Compliance (CE Mark) EEx d, IIB+H 2 ; T4 97/23/EC Pressure Equipment Directive (PED) 94/9/EC Potentially Explosive Atmospheres (ATEX) 02ATEX6051X 98/37/EC Machinery Directive 89/336/EEC Electromagnetic Compatibility Directive (E[...]

Figure 1-1. Typical HFG2. 0 Gas F uel System Installation Figure 1-2. Alternate HFG2.0 Gas Fuel System Instal lation Dimensions Figure 1-3 and Figure 1 -4 show external dimensio ns for the 3-piece housing and 1-piece housing version s of the HFG2.0, respectively. Mounting Considerations The HFG2.0 can be mounted directly t o a gas turbine engine sk[...]

6 HFG2.0 USER GUIDE 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 ver sion of the HFG2.0 are lo cated on the opposite side from the electrical connect ors. The mounting holes on t he reversed version of the HFG2.0 ar e located on th[...]

WARNING Explosion Hazard – Do not remove the clevis. Removing the clevis violates the warranty . Care should also be taken when rot ating the clevis or indexi ng the screw pattern to avoid scratchin g the flame path or introdu cing particulates to the assembly . Pipe Connections The standard pipe connection for the HFG2.0 is per SAE J518, -32 (2 [...]

8 HFG2.0 USER GUIDE Vent Port The gas leakage rate through th e vent port is less th an 200 cm 3 /hr (air or N 2 as t est flow). The vent port fe atures a 1/8-NPT fitting. See Fig ure 1-4. Consult local installation codes to determine whether and h ow to connect this port. Figure 1-3. HFG2.0 Dimensions, 3-Piece Housing[...]

Figure 1-4. HFG2.0 Dimensions, 1-Piece Housing INSTALLING THE HFG2.0 9[...]

10 HFG2.0 USER GUIDE Figure 1-5. HFG2.0 Mounting Orientations[...]

Figure 1-6. HFG2.0 Mounting Provisions, 3-Piece Hou sing (Standard Mounting Orient ation Shown) INSTALLING THE HFG2.0 11[...]

12 HFG2.0 USER GUIDE Figure 1-7. HFG2.0 Mounting Provisions, 1-Piece Hou sing (Standard Mounting Orient ation Shown)[...]

Figure 1-8. HFG2.0 Mounting Provisions, 1-Piece Hou sing (Reversed Mounting O rien tation Shown) INSTALLING THE HFG2.0 13[...]

14 HFG2.0 USER GUIDE 1.4 Electrical Connections The HFG2.0 is suitable for use in hazardous lo cations. See the General Specification Summary in Section 1 .2 for certifica tions. Ensure compliance with the factory recommendations, an d that wiring is in accordance with local require ments. WARNING: 94/9/EC (ATEX) Compliance – Special Condi tions [...]

Figure 1-9: HFG2.0 System Power Wiring Diagram Figure 1-10. Typical Powe r Con nection With Power Suppl y Figure 1-11. Typical Power Con ne ction With Battery WARNING - Shock Hazard Connect both the 120 V DC power and auxiliary wires. If onl y the primary power wires are conne cted, the 120 VDC auxiliary po wer wires are electrically live and must [...]

16 HFG2.0 USER GUIDE Note: A battery s ystem is recommen ded for highest reliabili ty. Note: If a 120 VDC po wer supply is used rathe r than a battery, ensure an output capacit ance of at least 12,00 0 µF, which can both sink and s ource electric current. See Po wer Supply Requirem ents (Ta ble 1- 2). Note: Use a sepa rate conduit for the power wi[...]

Therefore, it is not possible to correctly state a sing le capacitance value that should be placed on the bus. It may require no added bus capacitan ce or hundreds of thousands of microfarads of capacitance. A typical output capacitance value used f or non-battery power systems is 50,000uF, but the actual value depends on the specif ic power system[...]

18 HFG2.0 USER GUIDE Signal Connections Signals are sent between the HFG2.0 and the user’s controller t hrough the integral 17-wire signal harness. See Table 1-4 f or the wire list for this harness. See Figure 1- 12 for the system signa l wiring diagram. WIRE COLO R FUNCTION AWG WHITE/ORANGE/YELLOW Serial/RX In 20 WHITE/ORANGE/BLUE Serial/TX Out [...]

Figure 1-12: HFG2.0 System Signal Wiring Di agram Note: For proper operati on of the controller, the voltage be tween the control inputs and th e negative terminal of the power supply should be belo w 200 VDC. Note: The Serial Re turn is internally c onnected to the 120 VDC input Return. INSTALLING THE HFG2.0 19[...]

20 HFG2.0 USER GUIDE Analog In puts The analog input, DEMAND, has a current ra nge of 4 - 20 mA. It is electrically isolated up to 500 VAC from the enclosure, 120 VDC power, digital I/O, and serial interf ace. The analog inter faces are not isolated from each other. See Fig ure 1-13 for a typical analog input connection. HFG 2 .0 4-20 m A I N PU T [...]

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 connectio n. CO NTRO L LER DI S C R E TE INPU T HFG 2 . 0 DI S CRE TE O UTP UT F A ULT R T N [ WH T /O RN ] O V E RTEMP RTN [ WH T /B LK ] F A UL T ALAR M [ O R N] OV ER T EMP AL AR M [BL K ] CONTROLL[...]

22 HFG2.0 USER GUIDE FUNCTION Standard 9-Pin COM Port Standard 25-Pin COM Port Transmit (Tx). Pin 3 Pin 2 Receive (Rx) Pin 2 Pin 3 Ground (GND) Pin 5 Pin 7 Table 1-5. Com puter COM Port Pin Out s WARNING Property Damage Hazard – The serial inputs are not electri cally isolated . Failure to properly isolate t he user serial interface could result [...]

Recommended Wir ing for Sy stem Signa ls The recommended wiring is a 17-con ductor shielded cab le containing twisted-pair wires with in dividual 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 RECOMM[...]

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2 UNDERST ANDING THE HFG2.0 2.1 System Description The HFG2.0 is an electrically ope rated gas fuel-metering valve that requires only 120 VDC po wer, an analog fuel demand signal, an d a discrete RUN command to achieve ba sic operational capability. No pneumatic or hydraulic power is requir ed. The HFG2.0 is a closed loop servo system containing Mo[...]

26 HFG2.0 USER GUIDE 2.2 Electrical Description The electric actuator in th e HFG2.0 incorporates digital motor control electronics (MCE). The MCE contain anal og to digital converters, a digital signal processor (DSP), application specific integr ated circuit (ASIC) and power supplies. Figure 2-1 show s the system block diagr am. The MCE provides [...]

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 o rder to reset the controller and actua tor. DEMAND Signal The DEMAND signal is a user-provided analog inp ut that is used to control the position of the valve. The current level of the DEMAND signal is correlated to the positi[...]

28 HFG2.0 USER GUIDE Figure 2-1. HFG2.0 Electronics System Block Diag ram[...]

Alarms The HFG2.0 provides two two-wire alarm signa ls 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 Figur e 1-16 for typical connections. Refer t o the General Specification Summary Table in Section 1[...]

30 HFG2.0 USER GUIDE Note: The MCE an alog and discrete signa l interfaces are electrically isolated. T he serial communicati on interface is optically isolated 2.3 Mechanical Description The HFG2.0 consists of two main par ts, an actuator and a valve assembly. Actuator The actuator is the p rimary drive me chanism for the valve assembly. The actua[...]

monitor winding temperatures. The m otor electrical power and t hermistor wires pass through a cond uit into the electronics h ousing. Motor Rotor The motor rotor is locked to the ball screw shaft via a straigh t key. The motor rotor contains powerful magnets tha t align with the energized stat or windings, thereby creating torque and shaft rotatio[...]

32 HFG2.0 USER GUIDE Extension Rod and Bearings The extension rod is threa ded on the ball nut. A s the ball nut transla tes, the extension rod moves in and out of the HFG2.0 main housing. Counter-clockwise (CCW) rotat ion (facing the motor end of the actuator) of the motor rotor and screw shaf t results in the extension rod e xtending out of the m[...]

Orifice Assembly The orifice assembly cont ains a set of poppets an d orifice plates. Fuel flow is metered between the INLET po rt chamber and OUTLET port chamber in proportion t o the poppet position a nd resultant flow area. The poppet assembly is conne cted to the extension rod o f the actuator. As the actuator retract s, the poppet assembly ret[...]

34 HFG2.0 USER GUIDE Figure 2-2. HFG2.0 Cut-Away View – Actuator Main Housing Assem bly[...]

Figure 2-3. HFG2.0 Cut-Away View (Partial) CH. 2: UNDERSTANDING THE HFG2.0 35[...]

36 HFG2.0 USER GUIDE 2.4 Identification Plate A product identificatio n 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. H azardous area operation, certificat ion and electrica l wiring interface [...]

Figure 2-5. Typical Refurbishment Plate CH. 2: UNDERSTANDING THE HFG2.0 37[...]

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3 OPERA TING THE HFG2.0 This section refers to the position of the actuator when describing operation of the HFG2.0 v alve. The end of the actuator exten sion rod is connected to the poppet assembly of the valve. The linear mot ion of the actuator, both extension and ret raction, is directly translated to t he poppet assembly. The position of the a[...]

40 HFG2.0 USER GUIDE this point, the HFG2.0 has no info rmation about the position of the actuator extension shaft. When the HFG2.0 receives the RUN comm and, it will initiate motion in the homing direction. The default homing direction f or the HFG2.0 is “Extend”. This means that the first movement after Power Up or Reset will be an extension [...]

Figure 3-1. HFG2.0 Basic Operation Flow Chart CH. 3: OPERATING THE HFG2.0 41[...]

42 HFG2.0 USER GUIDE 3.4 Moving to S top Position The Stop position is a fail-safe position that may be set anywhere between Home (zero position, Valve Close d) and maximum span (maximum flow). The default value fo r Stop position is 0.0 inche s, as defined in the Set-Up parameters. The actuator will move to the Stop position if the DEMAND signa l [...]

Full Span Position (Maximum Flow) The Full Span (Maximum Flow) positi o n correlates t o 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. The Span value in t[...]

44 HFG2.0 USER GUIDE 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 Softw are. See the Section 3.8 for additional details about Set Up parameters. Figure 3-3. Dead Band of Act uator, Position vs. DEMAND Curve 3.6 Resetting the A[...]

3.7 Monitoring System Health The firmware program continuously monitors syste m health while the HFG2.0 is powered. If any of the healt h parameters are out of the normal operating range, t he MCE outputs a discrete fau lt alarm to the user’s controller. Some fault causes are: • MCE o ver-current • Tracking error • RDC failure • Input vol[...]

46 HFG2.0 USER GUIDE See Table 3-4 for a list of Over Temp conditions represented by t he OVERTEMP alarm in earlier generations of th e HFG. Fault File The HFG2.0 firmware also captures the fault data in the EEPROM. If the HFG2.0 is operational, a fault fi le can be downloaded using Act Wiz software via the RS232 int erface. The fault file will p r[...]

Fault Type Low Alarm High Alarm Fault Enable Persist Time Auto Reset Output Driver Overcurrent N/A 1000 lbf Yes 10 Sec Yes Yes Tracking Error N/A 3.33 % Yes 10 Sec Yes Yes Position Demand 3.5 mA 20.5 mA No 1 Sec No No RDC Failure N/A N/A Yes N/A No Yes +14 Volts 12.0 Volts 16.0 Volts Yes 7.5 Sec Yes Yes –14 Volts –16.0 Volts –12.0 Vo lts Yes [...]

48 HFG2.0 USER GUIDE Fault Alarm Type Persist Time Fault Action Driver Over Current 10 Sec 1 Sec Driver current > Max F orce equivalent current, Fault. Driver current > Max F orce equivalent current, Fault. If persists for 1 Min., Shutdown Driver current > 18 Amps, Fault. If persists for 1 Min., Shutdown Tracking Error 10 Sec If in RUN sta[...]

Fault Type Persist Time Fault Action Motor 10 Sec 1 Sec Motor temp > 130° C, Fault. . If fault exists and Motor temp > 135° C for 10 Sec, shutdown. Motor temp > 130° C, Fault . If fault exists and Motor temp > 130° C for 60 Sec, shutdown. Electronics 10 Sec 1 Sec Electronics temp > 110° C, Fault. If fault exists and Electronics [...]

50 HFG2.0 USER GUIDE 3.8 Changing Set-Up Parameters The HFG2.0 uses a number of variables to define its functionality. These variables are called Set-U p parameters and they are sto red in the EEPROM in the HFG2.0. Default values for these variables are loaded into the EEPROM at the PECC factor y. The Set-Up parameters are reloaded into the system [...]

PARAMETER DESCRIPTION FACTORY SETTING Part Number Describes pa rt number of a ctuator model Per Drawing Actuator Type Describes type of actuator Stand Alone Command Source Sets type of command si gnal Analog Home Controls the dire ction the actuator will move, extending or ret racting, to find the mechanical st op (HOME) Extend Span Sets the maximu[...]

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4 MAINT AINING THE HFG2.0 Under normal operation, the HFG2.0 requires no formal mainten ance program. Regularly scheduled inspections should be p erformed to check for: • any damage to wire insulation on integral 17-wire sig nal harness • any damage to wire insulation on integral 4-wire power harness • actuator-to-valve alignment (or actuat o[...]

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5 TROUBLESHOOTING This section provides troubleshooti ng information for the HFG2.0. You can isolate most ele ctrical faults by using an exte rnal oscilloscope and digital voltmeter (DVM) and computer with d iagnostic software. The HFG2.0 is comprised of highly reliable components and should not develop service problems under normal operating condi[...]

56 HFG2.0 USER GUIDE Symptom Probable Causes Corrective Action Valve Inoperative - FAULT alarm Power Wires not connected No or low 120 VDC power Ensure RED and GREEN wires correctly connected to valve Ensure 120 VDC Primary System Power at valve Valve Inoperative - NO FAULT alarm No RUN or position command Ensure VIOL ET and WHITE/VIOLET wires corr[...]

Symptom Probable Causes Corrective Action RS232 Int erface Inop erative Incorrect wiring No or low 120 VDC power COM1 not connecte d RESET or RUN co mmand is ON Ensure WHITE/ORANGE/YELLOW, WHITE/ORANGE/BLUE, WHITE/ORANGE/GREEN wires correctly connected to valve and laptop PC. Ensure 120 VDC Primary System Power at Valve Check laptop/PC com port Rem[...]

58 HFG2.0 USER GUIDE Function Actuator Wire Colors Resistance Value DEMAND BRN and WH T/BRN 225 Ω RUN VIO and WHT/VIO 4.7 K Ω RESET GRY and WHT/GRY 4.7 K Ω PO WE R RE D a nd G RE EN High Impedance, but not open circuit. MOTOR CURRENT BLU and WHT/BLU H igh Im pedance PO SI T IO N YE L a nd WH T /Y E L High Impedance FA UL T Ala r m OR N a nd WH T[...]

5.1 F AUL T File The FAULT and OVERTEMP alarms are discrete output s from the HFG2.0. The FAULT and OVERTEMP alarm circuits are closed in the normal operating condit ion. If the HFG2.0 de tects a fault, the alar m circuit for that fault opens, and t he user-provided controller should dete ct the open circuit. The fault is recorded in the fault f il[...]

60 HFG2.0 USER GUIDE Watchdog expired The MCE watchdog timer continuously monitors the firmware program. Should the MCE firmware program st op functioning, or attempt to acce ss an illegal address, the MCE sign als a fault. This fault does not clear without RESET command. Resolver to Digital Converter (RDC) fa ilure The MCE contains a resolver to d[...]

APPENDIX A: DECOMMISSIONING & DISPOSAL This section contains re commended 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 /ta gout procedures an d verify no live electrical circui[...]

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APPENDIX B: GLOSSAR Y Term Definition RUN Command A discrete 24 VDC signal that enabl es the HFG2.0 actu ator and valve to move. RESET Command A discrete 24 VD C signal that causes the HFG2.0 internal program (firmware) to jump to the be ginning. Controller A user-provided computer that exe cutes commands t o the HFG2.0 and accepts a nalog and disc[...]

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