ALTRONIC AGV5 SERVICE MANUAL GAS METERING VALVE
Contents
1. 0000000002000 000 9 TOP VIEW ACTUATOR ASSEMBLY PORT ASSEMBLY CONTROL HOUSING ASSEMBLY 2 0 PARTS IDENTIFICATION 21 PARTS LIST AGV5 Reference exploded view on 1A ITEM NO QUANTITY PART NO DESCRIPTION 1 1 PCB Field Retrofit Kit 1 1 PCB Assembly Logic 1b 1 Bushing Magnet 1c 1 Assembly Magnet Holder 14 4 Washer Flat 4 1e 4 Washer Lock 4 1f 4 Screw 4 40 11 1 Actuator Assembly 12 1 Control Housing Assembly 20 6 Bolt 1 4 28 x 2 L002 N S OL SLINN 44010 NO LSIX3 AVIN 64 343441 YONI 30 NOILVYNSIANOD LNAYYND SMOHS 41 NOILVOISILNAGI LIVd 91913 2 2 PARTS LIST AGV5 Reference exploded view on 1B ITEM NO 1 la 1b 1c 1d le 1f 2 2a 2b 2c 2d 2e 2f 29 2h 2i QUANTITY 1 eS ee ee ee 5 5 1 PART NO 881002 KT 872005 810114 810112 801008 801009 801010 820020 810033 810038 810035 810023 810024 810036 810037 810027 810025 810031 803020 801018 50303076 50303086 50303066 50303056 801015 801011 50303046 50301008 50303018 801014 50303026 50301096 50301106 8010022. from the 4 40 threaded stud Allen head set screw which holds it See FIG 1C The new magnet holder assembly 1c is installed by threading onto the 4 40 threaded stud NOTE When updating existing AGV5 units with S N 1400 or lower the obsolete pressure transducer and transducer housing assembly 19 MUST be replaced in addition to the PCB assembly 1a The obsolete pressure transducer is identified by the presence of four wires rather than three The obsolete transducer has a white wire in addition to the normal black red and green wires currently used The new pressure transducer and housing assembly with all required hardware is available completely assembled under kit part number 820022 A special magnet holder assembly 1c is supplied with this kit which will thread onto the 10 32 stud used on these older valves Replace the pressure transducer housing assembly 19 by sliding it over the new magnet holder assembly 1c and replacing the six Allen head mounting screws 26 holding it to the control housing assembly 12 Use the O ring lubricant 2k to help hold the O rings 2c and 2f in place under the pressure transducer housing assembly 19 Tighten the six Allen screws 26 to 18 20 inch pounds in order to hold the transducer housing assembly 19 to the control housing assembly 12 securely See section 5 0 for leak testing directions Leak test the valve before proceeding to H Place the new PCB assembly 1a onto the 4 40 stand
3. offs 28 on the top of the pressure transducer housing assembly 19 oriented as shown in FIG 1A and 1B Secure the PCB assembly 1a to the unit with the four Phillips head screws 10 flat washers 1d and lock washers 1e as shown Before tightening the screws 1f center the top of the magnet in the hole in the PCB as shown in FIG 1A Reconnect the wiring from the pressure transducer 27a to the three position terminal strip as shown in FIG 1A Cut off the plastic connector on the actuator leads and reconnect the actuator wires to the two position terminal strip as shown in FIG 1A Dress the wires appropriately taking care to not stress any connections or wires 3 5 Calibrating the position sensor A The following items are required to calibrate the position sensor when a new PCB assembly is installed a 24 volt power supply capable of supplying 5 amperes a GOV Display Module P N 891002 1 and a 4 20 milliampere simulator See FIG 2 for the AGV5 test stand wiring diagram Wire the components together as shown 14 Power the AGV5 and the Display Module will go to the HOME screen of the AGV5 program within 1 minute The HOME screen is shown below The first line of the display indicates the status of the valve with the input control current set to 4 milliamperes or less the valve is OFF or closed The second line of the display indicates the position sensor Hall Effect output voltage at this position of the valve 1 850
4. 50301166 820022 801006 DESCRIPTION PCB Field Retrofit Kit PCB Assembly Logic Bushing Magnet Assembly Magnet holder Washer Flat 4 Washer Lock 4 Screw 4 40 Valve Repair Kit O ring O ring O ring O ring O ring O ring O ring O ring O ring O ring O ring Lube Screw 10 32 Valve Seat Primary Valve Seat Secondary Spacer Poppet Metering Spring Screw 6 32 Perch Spring Assembly Actuator Assembly Control Housing Bolt 1 4 28 Guide Anti rotation Piston Balance Cap Balance Piston Washer Nut Pressure Transducer Housing Kit Screw 8 32 x 1 ATaWASSV 134404 55 LANSVIN SNISNOH YOLVNLOV NOILVOISILNAGI LYVd 21913 2 3 PARTS LIST AGV5 Reference exploded view on 1C ITEM NO QUANTITY PART NO DESCRIPTION 1 1 PCB Field Retrofit Kit 1 1 PCB Assembly Logic 1b 1 Bushing Magnet 1 1 Assembly Magnet Holder 14 4 Washer Flat 4 1e 4 Washer Lock 4 1f 4 Screw 4 40 2 1 Valve Repair Kit 2k 1 O ring Lube 20 1 Washer Flat 21 1 Cap Balance Piston 23 1 Piston Balance 24 1 Plug Hex 25 1 Nut Balance Piston 0091 N S S3ATVA 114 OL GWAYHL 29 01 V A18W3SSV 1 1VID3dS V SHGNMIONI OSTV LIM 220028 031541 GITANASSVIUA NMOHS SLNANOdWOD 6L LI 220028 LIM SLWGdN 404 3LON NOILVOISILNAGI LIVd Sis 2 4 PARTS LIST AGV5 Reference exploded view on FIG 1D ITEM NO QUANTITY PART NO DESCRIP
5. 7a is supplied in a kit 27 which includes all of the necessary parts NOTE When repairing or updating existing AGV5 units with S N 1400 or lower the obsolete pressure transducer and transducer housing as well as the PCB assembly MUST be replaced The obsolete pressure transducer is identified by the presence of four wires rather than three The obsolete transducer has a white wire in addition to the normal black red and green wires currently used The new pressure transducer and housing assembly with all of the required hardware is available and comes completely assembled under kit part number 820022 FIG 1B 19 A Remove the cover from the AGV5 housing by unscrewing it See fig 1A Use a spanner wrench or leather strap wrench to grip the cover Examine and make notes of the electronic board assembly 1 which show the wire routing and orientations 17 C Disconnect the transducer 27a from the electronics board 1a and remove the board 1a from the transducer housing assembly 19 Do not remove more wires than necessary D Using snap ring pliers remove the snap ring 27b holding the transducer 27a E With a small pry tool remove the transducer 27a from its housing F There an O ring 27c placed on the underside of the transducer 27a If this O ring 27c is damaged it must be replaced G Insert the new transducer 27a into position taking care to have O ring 27c in place within the cavit
6. ALTRONIC AGV5 SERVICE MANUAL GAS METERING VALVE FORM AGV5 SM 11 03 ALTRONIC 712 TRUMBULL AVE GIRARD OHIO 44420 GAS METERING VALVE AGV5 1 54 AGV5 2 AGV5 2A IMPORTANT SAFETY NOTICE PROPER INSTALLATION MAINTENANCE REPAIR AND OPERATION OF THIS EQUIPMENT IS ESSENTIAL THE RECOMMENDED PRACTICES CONTAINED HEREIN SHOULD BE FOLLOWED WITHOUT DEVIATION AN IMPROPERLY INSTALLED OR OPERATING VALVE SYSTEM COULD CAUSE PERSONAL INJURY TO OPERATORS OR OTHER NEARBY PERSONNEL TABLE OF CONTENTS SECTION 1 0 2 0 3 0 4 0 5 0 ITEM VALVE SERVICE AND REPAIR MANUAL OVERVIEW PARTS IDENTIFICATION REPLACEMENT OR UPDATE OF PCB ASSEMBLY REPLACEMENT OF THE PRESSURE TRANSDUCER PRESSURE TESTING OF AGV5 VALVE Ds ALTRONIC AGV5 SERVICE MANUAL PAGE 13 17 18 1 0 5 SERVICE AND REPAIR MANUAL OVERVIEW The AGV5 Gas Metering Valve has been designed to provide reliable operation with a minimum amount of maintenance To ensure optimum performance periodic inspection and cleaning is necessary Preventative maintenance issues can be integrated into the current maintenance schedule of the engine Most maintenance requires little effort and no downtime of the AGV5 valve Corrective maintenance is to be done when the AGV5 Gas Metering Valve begins to behave erratically Procedures have been generated to troubleshoot and to repair most minor issues External Visual Inspection Inspect the exterior of the valv
7. TION 1 1 PCB Field Retrofit Kit 1 1 PCB Assembly Logic 1b 1 Bushing Magnet 1 1 Assembly Magnet Holder 14 4 Washer Flat 4 1e 4 Washer Lock 4 1f 4 Screw 4 40 2 1 Valve Repair Kit 2k 1 O ring Lube 26 6 Screw 8 32 x 1 27 1 AGV5 Transducer Kit 27a 1 Assembly Pressure Transducer 27b 1 Snap Ring 27d 1 O ring Lube 28 4 Stand off 4 40 29 1 Housing Transducer 11 HOLVNLOV QNV1S 1531 tO OM HJONQSNVAL AYNSSAYd YOLVINNIS VUOZ v LNdLNO 02 gt SOTVNV NOILISOd SADV NMOHS SV SNId LOANNOO L 00 68 HOLHVOV YOLOANNOO ONISN LAdNI NOLLISOd 02 7 JHNSSIAHA 02 7 313349SIq z 31349sid 6854 TWIHIS Sersu IWINAS LAO JHNASSAHA 02 LNO NOILISOd 0Z r NHALIAH DQA 96 61 1 OAA 96 6 OQA 96 61 98754 1 5 98 5 IVIHAS 121314151617 81916 paver comunrcarion l Z00L68 N d JINQOM W 7 3 r H 9 4 3 q a 4 AATVA 5790 198340 AlddNS 11 GNVLS 1641 914 3 0 0 REPLACEMENT OF PRINTED CIRCUIT BOARD ASSEMBLY USING 881002 3 1 I 3 3 3 4 Retrofit installation of anew PCB assembly 1a can only be done by a qualified repair facility The valve must be remove
8. d from service and re calibrated and retested prior to use NOTE When updating existing AGV5 units with S N 1400 or lower the obsolete pressure transducer and transducer housing 19 MUST be replaced in addition to the PCB assembly 1a The obsolete pressure transducer is identified by the presence of four wires rather than three The obsolete transducer has a white wire in addition to the normal black red and green wires currently used The new pressure transducer and housing assembly with all required hardware is available completely assembled under kit part number 820022 Retain all removed parts in a small plastic bag These parts should be returned to Altronic Inc for exchange credit The following tools are required for the removal and installation of PCB assembly 1a a spanner or strap wrench a small Phillips head screw driver wire cutter strippers and an Allen wrench set Removing and replacing the older style PCB assembly A Disconnect the power from the AGV5 system at the source After power is off disconnect all field wiring at junction box B Remove the cover from the AGV5 housing by unscrewing it See FIG 1A Use a spanner wrench or leather strap wrench to grip the cover C Remove the old PCB assembly 1a by removing the four Phillips head screws 1f which secure it to the pressure transducer housing base 19 With the PCB assembly 1a loose locate the three wires black red and green coming from pressure tra
9. e for loose connections frayed wires or major structural damage Cleaning Exterior cleaning will aid in the visual inspection of the external casing and ensure good connections Ethyl alcohol or mild soapy water can be used as cleaning agents Maintenance Log facilitate troubleshooting and to establish service schedules a maintenance log should be kept on the valve Calibration Calibration of the AGV5 is performed in a controlled environment before shipment Since calibration of the valve requires equipment not normally available in the field it is recommended that the device be returned to the Altronic distributor serving your area Throughout this service manual service parts will be identified by the item number assigned to them in the parts list For example 1a its position inside the AGV5 device can be found by locating that item number on Fig 1A AGV UPDATES In addition to the standard procedures older AGV5 units below S N 1400 will require more items such as the pressure transducer and transducer housing to be changed These items and procedures are identified by specific notes When Updating Units below S N 1400 within the appropriate sections of the manual In addition to the repair of malfunctioning units instructions are given in SECTION 3 0 which describe the process of updating an AGV5 to the current configuration of PCB assembly FIG 1A PART IDENTIFICATION TERMINAL WIRING
10. nsducer 27a to the underside of the PCB assembly 1a Cut the wires from the old style PCB assembly as closely as possible to the PCB Locate the two wires coming from the actuator coil green and white and unplug the two pin connector coming from the underside of the old PCB assembly These five wires will be reused with the new PCB assembly 1a D Locate the wires coming from the existing LVDT assembly to the old style PCB assembly and cut them off Locate all of the tie wraps holding the old wiring harness to the housing and remove them Now remove the wiring harness and the old PCB assembly by pulling the old wiring back through the conduit going to the junction box These wires will not be used with the new PCB assembly 1a E Remove the pressure transducer housing assembly 19 by removing the six Allen head mounting screws 26 holding it to the control housing assembly 12 The pressure transducer housing 19 and the old LVDT coil can now be removed from the device Use an Allen wrench to loosen the set screw in the clamping end of the pressure transducer housing holding the LVDT coil and remove the LVDT coil The LVDT coil will not be reused Replace the LVDT coil in the pressure transducer housing with the magnet guide 1b See FIG 1D Tighten the Allen screw to hold the magnet guide 1b in the housing 29 securely 13 Remove the LVDT core from the shaft attaching it to the poppet assembly by carefully unscrewing the core
11. ough the valve from the input port to the output port when the valve is closed this is normal 18
12. r the MAXPOS value The 30 millivolt offset voltage ensures that the valve will be able to reach its wide open position regardless of minor system variations press to display next value press to press 0 press to increase decrease exit NORM value value setup mode 3 6 After returning from the position sensor calibration screen follow these instructions for testing the calibration of the AGV5 A The input simulator should still be set to 4 milliamperes or less and the HOME screen display should appear as shown below The position sensor voltage should be about the same as read in section 3 5 step B and the valve position shown in open should now read close to the fully closed position of 0 00 A reading of 0 00 0 50 would be in the normal range 16 B Adjust the input simulator to the values of current shown below and observe the display The values shown for open at each current input should now be calibrated to those shown in the table within a range of 0 50 8 milliamperes 25 12 milliamperes 50 16 milliamperes 75 20 milliamperes 100 C Measure the 24 volt power supply current to the AGV5 valve with the valve 100 open The current from the power supply should be 2 25 amperes or less 4 0 REPLACEMENT OF THE PRESSURE TRANSDUCERS 4 1 Replacement of pressure transducer 27a can be performed in the field under the direction of the distributor or Altronic personnel The transducer 2
13. volts in this case Read and record the actual voltage of the sensor This value is the MIN POS value The last characters XX XX of the second line of the display show the position of the valve in terms of open The open reading of the valve will not be correct until the valve is calibrated disregard the XX XX value shown at this time Increase the current from the simulator to 20 milliamperes and observe the display the proper display is shown below NOTE On valves below S N 2001 if the magnet does not move and the position sensor voltage on the display does not change reverse the green and white wires connecting to the actuator coil and retry The top line of the display indicates that the valve is operating in the position control mode and the desired set point from the simulator is for a 100 open condition The XXX XX value is the valve position based on the position sensor signal this value is incorrect until after the valve is calibrated Read and record the value shown on the second line for the position sensor voltage in the place of the 3 750 value in the example This value is the MAX POS value At this time reduce the input current signal from the simulator to 4 milliamperes or less before proceeding In order to program the position sensor calibration values into the AGV5 unit the configuration password must be entered in sequence When in the configuration mode all of the internal configuration values of the AGV5 are displa
14. y Use O ring lubricant 27d to help hold the O ring 27c in place H Re insert the snap ring 27b to hold the transducer in place See section 5 0 for leak testing directions Leak test the pressure transducer before proceeding to step 1 Route the three wires coming from the pressure sensor under the PCB assembly 1 to the terminal strip J Mount the PCB assembly to the pressure transducer housing Attach the wiring to the PCB assembly 1 in the proper orientation 5 0 AGV5 PRESSURE TEST 5 1 5 2 After repair and before returning an AGV5 valve to service the valve assembly must be pressure tested for leaks Using compressed air pressurize the valve assembly to 100 PSIG by blocking both the input and output ports Check for leaks using a solution of water and mild detergent NOTE Do not contaminate the electronics with the leak test solution Remove the PCB assembly to test the pressure transducer interface Leaks will be indicated by a steady stream of bubbles originating at the source Pay special attention to the interfaces between the pressure transducer housing 19 and the control housing assembly 12 the pressure transducer 27a and the pressure transducer housing 25 and the actuator assembly 11 and the port assembly See FIG 1 Ifa leak is detected remove all pressure before attempting to tighten fasteners to reduce leakage The AGV5 valve is not a shutoff valve There may be some flow thr
15. yed These values are never adjusted in normal use and should be accessed only by qualified personnel The first configuration screen is shown below After it appears press the SETUP key until the HARDWARE CONFIG screen shown in section 3 5D appears no other screen values will require adjustment from the factory default values to enter 5 then then configure press press mode F1 F2 SETUP press press to move to the next SETUP group 15 Press the setup key until the display shown below appears The sensor voltage value for the minimum open position can now be entered Recall the value read and recorded in section 3 5 step B This value plus 30 millivolts should be used for the MINPOS value The 30 millivolt offset voltage allows for a 0 00 output reading from the valve to any user equipment when it is off in spite of any thermal growth of the valve parts which may occur during normal use 2 to press to DE a 58111 LIN increase decrease value value The right arrow always points to the adjustable value on the CONFIGURATION screen Adjustments to CONFIG values are saved instantly and retained until changed again Use the UP arrow key to select the screen for the entry of the sensor voltage representing the maximum open position of the valve or 100 open Recall the value read and recorded in section 3 5 step C This value minus 30 millivolts should be used fo
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