Hamilton Sundstrand Company HFG2.0 User's Manual
Contents
1. 4 1 4 Electrical 14 2 UNDERSTANDING uuu suu 25 2 1 System DG SCM MOM 25 22 TOC UIC A ICS Ci ULU 26 2 9 1 T uuum 30 36 22 OPERATINCGOIIHETPIFO2 O Uu u u u au un aha ma 39 3 1 IIJ 39 3 2 Finding Home B ILU e 39 3 3 Holding Motor Current 51 40 Sx MOVING 0510 42 Lo CONTON 42 36 Ulta 44 3 1 Monitorning System CAMA LU LLULLU m UU 45 3 8 Changing Set Up 50 MAINTAINING THE TIFGO20 v 53 51 Reun Sn 53 1 91915123 meena ne ee eee 55 59 APPENDIX A DECOMMISSIONING amp DISPOSAL 61 PP INGE CLOS SART E 63 LIST OF FIGURES Figure 1 1 Typical2. 20 Figure 1 15 Typical Discrete Input Command Connection 20 Figure 1 16 Typical Discrete Output Alarm Connections 21 Figure 1 17 Typical RS232 Serial Interface Connection 21 Figure 2 1 HFG2 0 Electronics System Block Diagram 28 Figure 2 2 HFG2 0 Cut Away View Actuator Main Housing Assembly 34 Figure 2 3 HFG2 0 Cut Away View Partial 35 Figure 2 4 Typical Identification Plate 36 Figure 2 5 Typical Refurbishment Plate 37 Figure 3 1 HFG2 0 Basic Operation Flow Chalt 41 Figure 3 2 HFG2 0 Actuator Position vs DEMAND 43 Figure 3 3 Dead Band of Actuator Position vs DEMAND Curve 44 LIST OF TABLES Table 1 1 Wire List for HFG2 0 Power Harness 14 Table 1 2 Power Supply Requirements 16 Tabl
3. 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 HFG2 0 can be mounted directly to a gas turbine engine skid using brackets provided by the engine manufacturer The HFG2 0 can be mounted with any directional orientation whether horizontal vertical or at an angle The clevis must be supported if the HFG2 0 is mounted horizontally Valve life can be maximized if the HFG2 0 is mounted with the vertical orientation shown in Figure 1 3 or Figure 1 4 where the valve end is on the bottom The drain hole is most effective when mounted in this vertical orientation note The one piece housing version of the HFG2 0 does have drain hole INSTALLING THE HFG2 0 5 PRECISION A Hamilton Sundstrand Company 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 Figure 1 6 shows mounting provisions for the 3 piece housing version of the HFG2 0 Figure 1 7 and Figure 1 8 show mounting provisions for the
4. seems PN calming la Home 0 005 Home Pe ial meva papa is 4 08 mA and 4 1 mA dus hysberasiz 0 3 9 4 0 4 1 4 2 4 3 4 4 DEMAND Current mA Figure 3 3 Dead Band of Actuator Position vs DEMAND Curve 3 6 Resetting the Actuator To reset the HFG2 0 24 VDC must be applied across the RESET wires for at least 0 5 seconds The leading edge of the RESET command causes the HFG2 0 to stop all other operations but the actual resetting of the HFG2 0 does not begin until RESET is returned to its OFF state The RESET command causes the HFG2 0 to reset all internal position indicators reload all Set Up parameters and check the health of the electronics See the flow chart in Figure 3 1 for an illustration of this The HFG2 0 is now in the Power Up Reset state Once the RUN command is detected as ON the actuator will then move through its initial homing sequence again RUN and DEMAND inputs are ignored during the RESET command lf FAULT alarm is detected toggling the RESET command will clear the FAULT alarm but it will NOT clear the fault file 44 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 3 7 Monitoring System Health Fault Alarms 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
5. B4 nme s IFF MODL a PN 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 When a unit is refurbished by PECC a product refurbishment plate is also attached to the HFG2 0 housing assembly Figure 2 5 shows a typical refurbishment plate The refurbishment plate lists the original manufacture date refurbishment date refurbishment kit number and product revision number Te EST COLOR FUNCTI Pun 2 Sup B DIC 1 Gm Pun nh A feu Gan RE LAGE 1 D VM ATA CLE NT BH m MA REN Til Vil R S m Et RP qv Rh RE Ls RET omnl REM T Ary s KE VP A ARV W Mx cnn RM CUN om Cum FAL E il YIL 36 Figure 2 4 Typical Identification Plate 2 0 USER GUIDE PRECISION Hamilton Sundstrand Company 4 MANUFACTURE DATE O x REFURB DATE REFURB KIT NO REV 2 9 k Figure 2 5 Typical Re
6. Figure 1 9 HFG2 0 System Power Wiring Diagram POWER SUPPLY HFG2 0 120 VDC INPUT Figure 1 10 Typical Power Connection With Power Supply BATTERY HFG2 0 120 VDC INPUT 120 VDC Reverse Polarity Protection 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 INSTALLING THE HFG2 0 15 PRECISION A Hamilton Sundstrand Company 16 A battery system is recommended for highest reliability A Note 120 VDC power supply is used rather than a battery ensure an output capacitance of at least 12 000 uF which can both sink and source electric current See Power Supply Requirements Table 1 2 A Use a separate conduit for the power wiring This prevents noise pickup and transmission from ancillary equipment which could cause instability in the actuator Power Supply Requirements Table 1 2 below lists the power supply requirements for the HFG2 0 PARAMETER Voltage Nominal 120 VDC Range 80 160 VDC Max Ripple 4 RMS or 12 VAC Current Maximum 20 Amps Continuous Typical lt 1 Amp Transient Typical 20 A lt 60 ms 10 A lt 600 ms 5 100 ms Output Capacitance 12 000 uF typical Table 1 2 Power Supply Requirements
7. 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 Power sources used in the DC power system their output impedance transient response rating diode decoupling if any topology etc All electrical loads and components connected to each respective power bus branch Switching relationships of these electrical loads and components to each other for example does a large motor and actuator turn off at about the same time etc Bus branch conductor length and arrangement flat bus bars round cables twisted etc HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 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 50 000 but the actual value depends on the specific power system as discussed above It is best to test the power system for adequate capacitance by executing full stroke step changes with the actuator at the same time as all other devices on the bus are switched and measuring the bus voltage at the actuator power input point to verify that it does not dip below the minimum or exceed t
8. Driver current gt Max Force equivalent 10 Sec A A current Fault Driver Over Current Driver current gt Max Force equivalent 1 Sec current Fault If persists for 1 Min Shutdown ZA Driver current gt 18 Amps Fault If persists for 1 Min Shutdown ZN If in RUN state not in home dead band 10 Sec and position error gt allowable Tracking Error Fault A A AAA If not in overcurrent RDC not faulted and feedback not equal to demand Fault A If last reset was caused by watchdog Watchdog Expired lt 1 Sec timer timeout or illegal address attempt Fault RDC Failure lt 1 Sec Tests hardware for RDC failure sets Fault if RDC failure bit set Retract Extended N A Fault not used Command Unregulated Voltage Low Unregulated voltage low Fault 14 Volts Low 7 5 Sec AA 14 V supply 12 V Fault 1 Sec N AAA 14 Volts High 75 Sec AA 14 Volts Low 7 5 N N 14 V supply gt 12 V Fault OUT ea 14 Volts High 7 5 Sec AA 14 V supply lt 16 V Fault OUT mea AAA Input Voltage Low 7 5 Sec N N Input Voltage 75 V Fault 1 Sec ZN Input Voltage High 7 5 Sec AA Input Voltage 180 V Fault lt 1 Sec N AAA DSP Failure Fault not implemented Electronics Over Temp 10 Sec N Electronics temp gt 110 C Fault N Table 3 3 Fault Configuration For FAULT Alarm N N N 48 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company Fault Type Fault Action
9. Motor 10 Sec AA Motor temp gt 130 C Fault A N If fault exists and Motor temp gt 135 C for 10 Sec shutdown AA 1 Sec ZN Motor temp gt 130 C Fault If fault exists and Motor temp gt 130 C for 60 Sec shutdown Electronics 10 Sec AN Electronics temp gt 110 C Fault ZN 1 Sec If fault exists and Electronics temp gt 115 C for 10 Sec shutdown N Electronics temp gt 110 C Fault If fault exists and Electronics temp gt 100 for 15 Sec shutdown Table 3 4 Fault Configuration For OVERTEMP Alarm AN ZN Automatic Shutdown Feature The HFG2 0 has a self protective shutdown feature The HFG2 0 will shutdown if e Any two motor winding temperatures exceed 135 C for ten 10 seconds N N N or more 130 for 60 seconds AN e electronics temperature exceeds 115 C for 10 seconds N or more 100 C for 15 seconds A note The POSITION and MOTOR CURRENT feedback signals will both be set to 0 mA when the current to the actuator motor is removed WARNING Property Damage and Injury Hazard If the motor windings exceed 135 C 130 C or the electronics exceed 115 C 100 C A the MCE will shut down power to the motor and electronics thereby allowing the actuator to move with load When power is removed the return spring causes the poppets to return to the soft seats thereby closing the valve Touching the HFG2 0 may result in seriou
10. 1000 ft AWG 18 stranded gt 1000 ft Consult Factory Table 1 6 Wire Size for HFG2 0 Signal Harness Use a separate conduit for the signal wiring This prevents noise pickup and transmission from ancillary equipment which could cause instability in the actuator If conduit is not used signal wires should be at least 4 6 inches from any other wires Ensure that all shielded cables are twisted conductor pairs with either a foil or braided shield PECC recommends Belden 8719 shielded twisted pair audio broadcast and instrumentation cable All signal lines should be shielded to prevent picking up stray signals Connect shields as shown in Figure 1 12 Wire exposed beyond the shield should be as short as possible CAUTION This valve is 89 339 EEC EMC Directive compliant CE mark using watertight flexible conduit plastic over steel and Belden 8719 shielded twisted pair audio broadcast and instrumentation cable Use of other conduit or wire invalidates EMC Directive compliance Do not connect 24 VDC power without current limiting 25 mA across digital or analog outputs INSTALLING THE HFG2 0 23 PRECISION A Hamilton Sundstrand Company 24 PRECISION A Hamilton Sundstrand Company INTENTIONALLY BLANK HFG2 0 USER GUIDE PRECISION Hamilton Sundstrand Company 2 UNDERSTANDING THE HFG2 0 2 1 System Description The HFG2 0 is an electrically operated gas fuel metering valve that
11. motor bearing and spacers are all stacked on the ball screw shaft and retained by a single nut This arrangement prevents actuator axial loads from passing through the resolver rotor and motor rotor The end of the extension rod is connected to the poppet assembly of the valve The linear motion of the extension rod both extension and retraction is directly translated to the poppet assembly Valve The valve portion of the HFG2 0 consists of four main components e Valve Housing Assembly e Orifice Assembly e Soft Seats e Return Spring Valve Housing Assembly The valve housing assembly may be either three pieces or one piece The three piece version consists of upper center and lower valve body sub assemblies which are bolted together with eight 72 diameter high strength steel bolts The assembly is made of either machined aluminum or stainless steel The one piece version consists of a cast aluminum main pressure vessel and valve cover assembly The cover assembly attaches to the bottom of the vessel This version does not have a drain port See Figure 2 3 32 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 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
12. system is the linear ball screw drive containing a screw shaft ball bearing fitted nut extension rod and main duplex thrust bearings See Figure 2 2 Screw Shaft The thrust bearings motor rotor motor end bearing and resolver rotor are mounted directly to the screw shaft A ball bearing track is machined into the screw shaft Ball Nut As the screw shaft rotates the ball nut translates the rotary motion into linear motion along the shaft axis The direction of movement along the shaft axis is determined by direction of rotation CH 2 UNDERSTANDING THE HFG2 0 31 PRECISION A Hamilton Sundstrand Company 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 Clockwise CW rotation results in the extension rod retracting back into the main housing The extension rod support bearing is provided for lateral support Thrust and radial loads are transferred from the extension rod through the ball nut to the main preloaded duplex thrust bearings The thrust bearings transfer the loads to the main housing by the main bearing and shaft retaining nuts A motor end bearing is provided for additional radial shaft stability The resolver rotor motor rotor
13. the position that correlates to that current level See nterpolation of DEMAND Signal below Hysteresis Band The actuator should return to the Home position when the DEMAND Signal drops below the 4 1 mA Dead Band threshold In practice hysteresis may result in the actuator not returning to Home position until the DEMAND signal drops below a threshold as low as 4 08 mA The DEMAND signal range between 4 08 mA and 4 1 mA is therefore considered the Hysteresis Band See Figure 3 3 HFG2 0 USER GUIDE PRECISION Hamilton Sundstrand Company 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 The Span value in the Set Up parameters has a default setting of 1 0 inches of retraction to allow for the distance between the mechanical stop in the valve and the mechanical stop in the actuator The default definition of Home is Extend so default Span is a retraction Interpolation of DEMAND Signal Actuator Position inches Linear interpolation of the DEMAND signal in the range between 4 mA and 20 mA is the default condition as specified in the Set Up parameters With linear interpolation a DEMAND signal of 12 mA midway in range of DEMAND signal
14. 1 piece housing version of the HFG2 0 A note Provide adequate clearance to the OUTLET port to facilitate cleaning Lifting Considerations The aluminum body HFG2 0 weighs approximately 100 lbs The stainless steel HFG2 0 weighs approximately 190 lbs PECC recommends using the 0 375 inch diameter clevis to lift the valve in conjunction with the appropriate lifting equipment A The clevis exceeds the Factor of Safety FOS requirement of 3 based on component yield strength per ASME B30 20 1999 WARNING Lifting Hazard Do not attempt to hand lift the actuator Use appropriate lifting equipment Connecting the Clevis The clevis can be used to secure the actuator end of the HFG2 0 A high strength shoulder bolt 0 375 diameter is recommended to fasten the clevis to a user provided mount bracket The clevis can be rotated to any orientation to support installation Loosen the four retaining screws and rotate to the desired angle The screw pattern can be indexed 45 degrees to provide additional adjustment When adjustments are complete torque the four retaining screws to 117 138 in lbs HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company WARNING 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
15. A of the OVERTEMP alarm CH 3 OPERATING THE HFG2 0 45 PRECISION A Hamilton Sundstrand Company See Table 3 4 for a list of Over Temp conditions represented by the OVERTEMP alarm in earlier generations AA 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 The fault file will provide fault information and possible causes The HFG2 0 must be in the Power Up Set Up state to download the fault file See Section 3 8 for details about the Power Up Set Up state Contact Precision Engine Controls Corporation to request ActWiz software Toggling the RESET command will clear the fault alarm but it does NOT clear the fault file oee Section 5 Troubleshooting for a more detailed list of fault causes Note The fault file only records the programmable faults that have been enabledA 46 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand ompary BRUM SN MEAE NE SU waru Alarm Time E Driver Overcurrent Driver Overcurrent 100 100 10Sec 10Sec as s lt ss maa Table 3 1 Default Configuration For FAULT Alarm N mw epum ee es Alarm Alarm Enable Time Table 3 2 Default Configuration For OVERTEMP Alarm N CH 3 OPERATING THE HFG2 0 47 PRECISION A Hamilton Sundstrand Company Fault Alarm Type Fault Action
16. DC Motor Control Alama LS Orertonp Alarm ATH sisi aen Ball Screw Seda TX OUT maau RS 232 Sada RX Driver Serial M malu OPTICALLY ISOLATED valve Assembly Figure 2 1 HFG2 0 Electronics System Block Diagram 28 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 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 See Section 3 7 for additional details about alarms FAULT Alarm The fault configuration for the FAULT alarm is programmable in the most recent generation N of the HFG2 0 factory configurable only If a fault condition occurs the FAULT alarm switch will open interrupting the circuit with the user s controller See Table 3 1 for the default configurationZ See Table 3 3 for a list of fault conditions represented by the FAULT alarm in earlier generations N N of the HFG2 0 OVERTEMP Alarm The fault configuration for the OVERTEMP alarm is programmable in the most recent generationZA of the HFG2 0 factory configurable only If a fault condition occurs the OVERTEMP alarm switc
17. HFG2 0 Gas Fuel System Installation 5 Figure 1 2 Alternate HFG2 0 Gas Fuel System Installation 5 Figure 1 3 HFG2 0 Dimensions 3 Piece HOUSING 8 Figure 1 4 HFG2 0 Dimensions 1 Piece HOUSING 9 Figure 1 5 HFG2 0 Mounting Orientations 10 Figure 1 6 HFG2 0 Mounting Provisions 3 Piece Housing Standard Mounting 11 Figure 1 7 HFG2 0 Mounting Provisions 1 Piece Housing Standard Mounting 12 Figure 1 8 HFG2 0 Mounting Provisions 1 Piece Housing Reversed Mounting 13 Figure 1 9 HFG2 0 System Power Wiring Diagram 15 Figure 1 10 Typical Power Connection With Power Supply 15 INSTALLING THE HFG2 0 i PRECISION A Hamilton Sundstrand Company 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
18. N Failure to properly isolate the user serial interface 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 The serial inputs are not electrically isolated If power input is floating not grounded serial connections may have up to 120 VDC present Property Damage Hazard DO NOT connect 24 VDC power to any of the serial interface connections A note The pin designations shown in Table 1 5 are for the COM port on the computer Make sure that the wiring to the COM port mating connector correctly matches Transmit from the HFG2 0 to Receive on the computer s COM port and vice versa A Note The maximum distance for serial connections is 50 ft This will typically only allow for local interface with a laptop PC A note The serial interface connections are not isolated Isolation must be provided when computer 2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company Recommended Wiring for System Signals The recommended wiring is 17 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 RECOMMENDED CONTROLLER WIRE SIZE Minimum lt
19. The MCE signals a fault if the reference voltage drops below minimum for ten 10 seconds AN If the voltage returns to acceptable level the fault signal is cleared 14V High Low The MCE signals a FAULT if the internal 14 VDC power supplies exceed operating limits This fault does not clear without RESET command Input voltage High Low The MCE signals a fault if the 120 VDC supply exceeds 180 VDC or drops below 75 VDC for more than 7 5 seconds AX N 1 second for AN This fault clears when the 120 VDC supply voltage returns 60 HFG2 0 USER GUIDE PRECISION Hamilton Sundstrand Company APPENDIX A DECOMMISSIONING amp 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 e Disconnect the 4 wires of the integral power harness to the HFG2 0 e Disconnect the 17 wires of the integral signal harness to the HFG2 0 Disconnect the ground wire from the HFG2 0 chassis e Disconnect the fuel inlet pipe e Disconnect the fuel outlet pipe Note Follow local environmental codes in regards to disposal of electronic components specifically all electrolytic capacitors APPENDIX A DECOMMISIONING 61 PRECISION A Hamilton Sundstrand
20. The serial communication interface is optically isolated AA 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 e Main Housing Assembly e Brushless DC Motor Assembly e Resolver Assembly e Linear Drive Mechanism Housing Assembly The main housing assembly consists of the main housing motor cover extension rod bearing and associated seals The main housing assembly Is the primary structural system component and supports all the bearings motor cover mountings and connectors It also provides explosion proof containment The housing is fitted with a stainless steel liner to provide thermal and dimensional stability for the main bearing This liner is permanently installed into the aluminum main housing A retaining ring is included for redundant retention The main housing also contains rigid mechanical stops to prevent extension rod travel beyond the design specification See Figure 2 2 Brushless DC Motor Assembly A brushless DC motor powers the HFG2 0 linear drive mechanism The DC motor consists of a stator and rotor See Figure 2 2 Motor Stator The motor stator is attached to the main housing by a pre loaded wave spring and screws Thermistors are embedded in the stator windings to 30 HFG2 0 USER GUIDE PRECIS
21. actuator retracts the poppet assembly retracts to increase the flow area between the poppets and the two orifices As the actuator extends the poppet assembly extends to reduce the fuel exposure from the INLET port chambers to the two orifices When the actuator is fully extended the poppets seat in the orifices to close the valve See Figure 2 3 Soft Seats The orifices contain pressure energized soft seats and metal to metal hard seats which provide a leak tight seal when the poppets are ina closed position See Figure 2 3 Return Spring A pre loaded fail safe spring is located between the valve housing and poppet assembly The spring load increases as the valve opens If a power failure occurs the spring causes the poppets to return to the soft seats thereby closing the valve See Figure 2 3 CH 2 UNDERSTANDING THE HFG2 0 33 Figure 2 2 HFG2 0 Cut Away View Actuator Main Housing Assembly 2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company Power Electric Aciuatar L E n 1 Oynamic Seal REA m NF irum Fa EM a 2 Figure 2 3 HFG2 0 Cut Away View Partial 2 yf J 1 Soft Saal CH 2 UNDERSTANDING THE HFG2 0 35 PRECISION Hamilton Sundstrand Company 2 4 Identification Plate ite pg ead 21060 Cad HO TTIBF 4S
22. remove the RUN command during power up If a RUN command is given during the Set Up parameter download phase of power up the valve will not respond until the download is complete and the Home position has been established 3 2 Finding Home Position When the program is complete with a status check it waits for the RUN command When the status check and other steps in the Power Up Reset process are complete the HFG2 0 will wait until it receives the RUN command At CH 3 OPERATING THE HFG2 0 39 PRECISION A Hamilton Sundstrand Company 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 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 The actuator will extend at the rate specified by the Homing Velocity in the Set Up parameters default is 0 5 in sec until a mechanical stop is encountered In the HFG2 0 this stop reached when the poppets seat in the orifices thus closing the valve The HFG2 0 recognizes that a mechanical stop has been reached when the actuator velocity drops to 0 05 in sec or less The HFG2 0 will then slowly increase the motor current until the current level corresponding to the Maximum Homing Force has been applied This Maximum Homing Force is also specif
23. 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 The valve closes its own control loop on a position feedback signal from an internal resolver Thus the valve continuously modulates its position and provides precise fuel metering Gas fuel enters the valve flow body assembly INLET port The fuel flow is evenly split via a contamination deflector and pressure balanced orifice assembly as it enters the INLET port chamber The orifice assembly contains a set of poppets and control orifices As the valve actuator retracts the poppet assembly exposes fuel from the INLET port chamber to the two orifices The fuel flows through in the annulus between each poppet and fixed orifice and recombines in the OUTLET port chamber The fuel exits through the OUTLET port Flow is metered between the poppets and control orifices in proportion to the poppet position and resultant flow area The flow area ranges from zero with a Demand signal at of its range to maximum with Demand signal at 100 of its range The orifices contain pressure energized soft seats and metal to metal hard seats which provide a leak tight seal when the poppets are in a closed position A pre load
24. the user s controller Some fault causes are e MCE over current e Tracking error e RDC failure e Input voltage out of range The HFG2 0 features two discrete non latching outputs that are configured as fault alarms Upon power up the fault circuits close and stay closed in the normal operating condition When the HFG2 0 detects a system fault it opens the fault circuit designated for that particular fault If a fault alarm is detected the user should shut down the HFG2 0 to investigate the failure cause Removing 120 VDC power shuts down the HFG2 0 valve Toggling the RESET command will clear the alarms FAULT Alarm The configuration of faults assigned to the FAULT alarm is programmable in the most recent generation N of the HFG2 0 factory configurable only See Table 3 1 for the default configurationA of faults assigned to the FAULT alarm See Table 3 3 for a list of fault conditions represented by the FAULT alarm in earlier generations N ZA N of the HFG2 0 OVERTEMP Alarm The configuration of faults assigned to the OVERTEMP alarm is programmable in the most recent generation N of the HFG2 0 factory configurable only In the default configuration the Motor Over Temp fault is the only fault assigned to the OVERTEMP alarm If the HFG2 0 detects that the temperature in two or more of the motor windings is 135 C or higher the OVERTEMP alarm circuit opens See Table 3 2 for details about the default configuration
25. will correlate to a position at 0 5 inches midway in the 1 0 inch span See Figure 3 2 for an illustration of linear interpolation A uote The actuator and valve position is linear relative to the DEMAND signal in the default condition However due to the physical profile of the poppets orifices and soft seats the resultant flow area will NOT be linear relative to the DEMAND signal Maximum Span Actuator Posilion is Relalive to Mechanical Stop in HFG2 0 full extension as Home 0 6 Stop Position 0 1 inches Shown with Defaultof 0 4 Linear Interpolation Home Position from 4 to 20 mA 0 inches Sea Naxt Figure for Details 0 2 0 4 0 6 0 8 0 100 120 140 160 480 200 DEMAND Current mA Figure 3 2 HFG2 0 Actuator Position vs DEMAND with default conditions Home as a Mech Stop in HFG2 0 3 OPERATING THE 2 0 43 PRECISION A Ham itan Sundstrand Company 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 0 1 5 EM ERES 0 020 Actuator Position 0 015 Isa swan pota d Until 2emand is 2 2 1 and Default of 0 040 Span 1 0 I c188 Dead Band 00828 r sos
26. 20 VDC Primary System Power at Valve COM1 not connected Check laptop PC com port RUN command is Remove RESET or RUN command Table 5 1 Initial Installation Troubleshooting Chart Symptom Probable Causes Corrective Action No valve feedback No or low 120 VDC power Ensure 120 VDC at valve Self protective valve auto shut Upload Fault File check for motor windings over down temperature faults Check for valve contamination FAULT alarm Various Upload Fault File to identify source of fault Clear indicated fault OVER TEMP alarm Ambient temperature limit Allow actuator to cool and re start exceeded Reduce ambient temperature Electronics or motor winding Check for valve contamination temperature out of range FAULT and OVERTEMP No 120 VDC Power Ensure 120 VDC at actuator alarm DSP Failure Contact factory Table 5 2 HFG2 0 In Service Troubleshooting Chart For troubleshooting purposes use Table 5 3 to verify the valve electrical continuity integrity Disconnect the HFG2 0 power and digital harness connectors and use a digital multi meter DMM to check the resistance values between the wires indicated on the table If an open circuit is detected send the HFG2 0 to Precision Engine Controls Corporation for test and repair WARNING Shock Hazard Remove all power to the HFG2 0 prior to continuity check CH 4 TROUBLESHOOTING THE HFG2 0 57 PRECISION A Hamilton Sundstrand Company POWER RED and G
27. 7 VIFW Figure 1 6 HFG2 0 Mounting Provisions 3 Piece Housing Standard Mounting Orientation Shown INSTALLING THE HFG2 0 11 PRECISION Hamilton Sundstrand Company 500 002 12 7203 05 I 438 52 4 UNC 2H 2 50 127 OCKING HELICGIL z120 4 31 110 2 3 459 87 6 d bo n 1 5 gt TI Z NI 46 4 1250 31 7 2 500 63 5 5 65 92 7 32 35 5 250 20 JNC 2B 46 4 3 50 12 7 BONDING HOLE GND YLW Figure 1 7 HFG2 0 Mounting Provisions 1 Piece Housing Standard Mounting Orientation Shown 12 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 4 852 5 UNC 7H 072 50 12 7 OCKING HELICOIL I II 250 20 NC 2B 4 v 50 12 7 BJNDNU HOL GND B B Figure 1 8 HFG2 0 Mounting Provisions 1 Piece Housing Reversed Mounting Orientation Shown INSTALLING THE HFG2 0 13 PRECISION Hamilton Sundstrand Company 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 n
28. 7 EC Machinery Directive 89 336 EEC Electromagnetic Compatibility Directive EMC Materials Actuator Housing 6061 T6 Anodized Aluminum Valve Housing 6061 T6 Anodized Aluminum 316 Stainless Steel Optional Conduit Union Zinc Plated Steel Seals Viton and Teflon Connectors Aluminum 100 Ibs Max Aluminum Valve Housing 3 piece 85 lbs Max Aluminum Valve Housing 1 piece 190 Ibs Max Stainless Steel Valve Housing 3 piece 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 An alternate arrangement is shown in Figure 1 2 In this installation the HFG2 0 is located between two normally closed gas shut off valves Fuel Filtering For efficient valve operation filter the fuel through a 40 micron absolute filter before it reaches the valve This extends the time between routine maintenance Locate the fuel filter as close as possible to the valve INLET 4 HFG2 0 USER GUIDE PRECISION Hamilton Gundstrand Company RELAY rS SEMI SOSH Ms SHUTZFP GUTOFF auon FOL Figure 1 1 Typical HFG2 0 Gas Fuel System Installation PEL 86 LaRY IU RH as HERON
29. Company 62 PRECISION A Hamilton Sundstrand Company INTENTIONALLY BLANK HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 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 A discrete 24 VDC signal that causes the HFG2 0 internal program firmware to jump to the beginning A user provided computer that executes commands to the HFG2 0 and accepts analog and discrete feedback 4 mA to 20 mA signal that commands the HFG2 0 to move to a certain actuator valve position The signal is scaled with SPAN 4 mA to 20 mA signal that communicates the actual HFG2 0 actuator valve position to the controller 4 mA to 20 mA signal that is proportional to the HFG2 0 motor current The signal is scaled with Max Force A discrete signal from the HFG2 0 that communicates an internal failure The user s controller will see an open circuit when a FAULT alarm is active A discrete signal from the HFG2 0 that communicates an internal over temperature electronics or motor The user s controller will see an open circuit when the OVERTEMP alarm is active A mechanical rigid stop from which the HF
30. G2 0 Power The HFG2 0 operates on an input voltage of 120 VDC nominal that is provided by the user via an integral four wire power harness Refer to Figure 1 10 or 1 11 for a typical connection Refer to the General Specification Summary Table in Section 1 2 for load specification values Control Signals The HFG2 0 accepts three two wire external control signals via the integral 17 wire signal harness Refer to Figures 1 13 and 1 15 for typical connections Refer to the General Specification Summary Table in Section 1 2 for signal specification values RUN Command The user provided RUN command is a discrete input The RUN command must be ON to enable the HFG2 0 to perform the homing sequence after resetting or powering up The RUN command also enables the HFG2 0 to track the DEMAND signal The valve will move to the Stop Position if the RUN command is set to OFF or lost RESET Command The RESET command is a user provided discrete input to the HFG2 0 This command causes the HFG2 0 to reset all internal position indicators reload all set up parameters and to then move the valve through its initial homing sequence again The RUN command must be set to ON before the homing sequence can begin RUN and DEMAND inputs are ignored 26 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 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
31. G2 0 calculates position HOME is found at start up during the Homing sequence The HFG2 0 defines HOME when the motor current exceeds the HOMING FORCE and velocity is zero HOME is defined as the actuator valve position when the Demand signal is 4 mA HOME is the Valve Closed condition for the HFG2 0 When the HFG2 0 extends or retracts to find a rigid mechanical stop Maximum distance from HOME SPAN is defined as the position when the Demand signal is 20 mA A user defined position between HOME and SPAN that the HFG2 0 travels to upon loss of RUN or position Demand signal A user defined maximum velocity in inches per second A user defined maximum homing force output setting The motor control electronics uses this setting to determine the maximum motor current in the Homing sequence A user defined maximum force while in the Holding Motor Current state APPENDIX C GLOSSARY 63 PRECISION A Hamilton Sundstrand Company 64 PRECISION A Hamilton Sundstrand Company INTENTIONALLY BLANK HFG2 0 USER GUIDE
32. ION A Hamilton Sundstrand Company 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 Resolver Assembly A brushless non contacting resolver is the primary HFG2 0 feedback sensor Resolver excitation is achieved via a sinusoidal signal from the MCE The resolver provides two sinusoidal feedback signals back to the MCE The resolver assembly includes a stator and rotor See Figure 2 2 Resolver Stator The resolver stator is clamped to the main housing between the main bearing retaining nut and resolver retainer The angular position of the resolver stator relative to the resolver rotor is adjustable Electrical wires from the resolver are reeled in the resolver adapter to allow rotation The resolver wires along with the motor and thermistor leads pass through a conduit into the electronics housing Resolver Rotor The resolver rotor is mounted to the ball screw shaft by a key As the rotor rotates the stator transformer output signals provide shaft rotation information to the MCE Linear Drive Mechanism The Linear Drive Mechanism converts the rotary motion of the Motor Assembly to linear actuator motion The core of the mechanical drive
33. ITE ORANGE VIOLET WHITE VIOLET GRAY WHITE GRAY BROWN WHITE BROWN YELLOW WHITE YELLOW BLUE WHITE BLUE FUNCTION Serial RX In Serial TX Out Serial RETURN OVER TEMP Alarm OVER TEMP Alarm RETURN FAULT Alarm FAULT Alarm RETURN RUN Command RUN Command RETURN RESET Command RESET Command RETURN Position Demand Position Demand RETURN Position Feedback Position Feedback RETURN Motor Current Motor Current RETURN Table 1 4 Wire List for HFG2 0 System Signal Harness HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company Engine Controller 2 0 DEMAND Darerc DEMAND RTH IE Le ded ait Hun RUN Rur RUN RTH PAHTA Tr Uu lud ie Ge mk RES ET ATH T Gal Mom MTR CURRENT BLU Gurt ATR CURRENT RTH PRHTABLUJ IE L Er Far ama Prien PO LEOM YH Post or ATH Fired Faut Alarm FAULT ALARM CORN Fak Alarm FALLT ALARM f Over Alam CVFRIHAP Al AMR Char lone Alarm ALARM RTH PELIS Pe Bhield GHD Shield in SERIAL TX QUT TX qu SERIAL RA IH FTM PA Dea H
34. LLY BLANK 54 HFG2 0 USER GUIDE PRECISION Hamilton Sundstrand Company 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 HFG2 0 is comprised of highly reliable components and should not develop service problems under normal operating conditions However over a period of time and service failures may develop Whoever is responsible for fault analysis should be thoroughly acquainted with physical and electrical configurations Theory of Operation Section 2 and Installation Section 1 Resolve problems noted during operation or maintenance as soon as possible The causes of many problems can be traced through the information contained in the block diagram shown in Section 2 CAUTION Continuing to operate the valve in a malfunctioning condition is hazardous to personnel and can cause property damage Tables 5 1 and 5 2 list common failures that can occur before or after valve installation respectively In addition the HFG2 0 has on board troubleshooting capability The ActWiz software has a fault file that you can upload to pinpoint a failure cause See the ActWiz Software Manual for more details If after following the troubleshooting procedures you still can t find the cause of the problem and repair it contact the factory for ass
35. ME position Maximum Homing Force Sets the maximum force the HFG2 0 will 500 Ibf use to find the HOME position Maximum Holding Force Sets the maximum force to be used to 500 Ibf hold at the HOME position while the position demand is 4 1mA and 2mA Table 3 5 Typical HFG2 0 Setup Parameters With Default Values 3 000 CH 3 OPERATING THE HFG2 0 51 PRECISION A Hamilton Sundstrand Company 52 PRECISION Hamilton Sundstrand Company INTENTIONALLY BLANK HFG2 0 USER GUIDE PRECISION Hamilton Sundstrand Company 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 any damage to wire insulation on integral 17 wire signal harness any damage to wire insulation on integral 4 wire power harness actuator to valve alignment or actuator to load alignment any damage to housing or mounting hardware any damage to power and signal harnesses parts that are worn loose or shifted due to shock vibration etc 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 CH 4 MAINTAINING THE HFG2 0 53 PRECISION A Hamilton Sundstrand Company PRECISION A Hamilton Sundstrand Company INTENTIONA
36. PRECISION Hamilton Sundstrand Company 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 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 Operating the HFG2 0 Gas Fuel Metering Valve in accordance with instructions herein ensures long term and reliable operation If you need additional information please contact Precision Engine Controls Corporation 11661 Sorrento Valley Road San Diego California 92121 858 792 3217 e 800 200 4404 Fax 858 792 3200 E mail peccntl precisioneng com 2006 PRECISION ENGINE CONTROLS CORPORATION ALL RIGHTS RESERVED PRECISION A Hamilton Sundstrand Company TABLE OF CONTENTS POSS OFTAS OUG uuu unu Zana lil Pi HIGENN WO uu u u What the User Should IV kalded Te ipi NM IV EE IPSA ICHILIMuLiC0U 1 gt lt ee ee ee 1 1 2 General Specification 3 1 3 Mechanical nstallation
37. REEN High Impedance but not open circuit MOTOR CURRENT High Impedance POSITION High Impedance FAULT Alarm High Impedance OVERTEMP Alarm High Impedance Table 5 3 HFG2 0 Electrical Continuity Troubleshooting Chart 58 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 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 The fault is recorded in the fault file The HFG2 0 firmware 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 The fault file will provide fault information and possible causes The HFG2 0 must be in the Power Up Set Up state to download the fault file See Section 3 8 for details about the Power Up Set Up state Contact Precision Engine Controls Corporation to request ActWiz software Should a fault occur the user should shut down to troubleshoot the failure Removing 120 VDC power shuts down the HFG2 0 Toggling the RESET command will clear the fault but it does NOT clear the fault file note The fault file only records the programmable faults that have been enabled N Fault Descriptions The following are brief description of some of the fau
38. T AND 4 3 6 la 26 132 0 3 4 NPT POWER IN TEXFACE 208 306 8 3 4 NPTF SIGNAL INTERFACE 15 55 339 1 Figure 1 3 HFG2 0 Dimensions 3 Piece Housing HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 58 141 8 5 244 1 87 45 7 X 132 73 4 m 4 NPT POWER 17 08 508 77 5 600 2 34 S NP F SIGNAL INTERFACE 10 48 7266 4X8 50 13 NC 2B 12 7 21 00 25 4 LOC4 13 35 7334 F OW 4 75 120 7 2 00 HA da CGODF61 4 ROLI INIHI AND Oull FI 4 100 104 1 26 90 183 1 J00 956 Figure 1 4 HFG2 0 Dimensions 1 Housing INSTALLING THE HFG2 0 9 PRECISION A Hamilton Sundstrand Company ORIENTA TOI v ORIENTE TON S AMDARD MOUNTING REVERSED MOLNTIAG Figure 1 5 HFG2 0 Mounting Orientations 10 HFG2 0 USER GUIDE PRECISION Hamilton Sundstrand Company 4 20 2 28 712 7 DCNDINO 017 EL A 1 37 m 4 38 111 3 4 650 11 23 2 7 VIW C _ C v 50 17 7 2 2 H 4 22 7107 2 u 4 13 781 0 1 5 22 1334 2 15 941 B 7 52 152 Lm DRAIN P UG TI Z n d 8 21 7208 5 gt 2 00 52 8 5 53 I z 45n Z 5C 6 5 5
39. Where unique information applies to a specific generation one of the following symbols will be shown to indicate as such A Fourth generation isolated RS 232 P Ns 5002605 XXX 5002610 XXX 5002447 XXX or Any Remanufactured Part with Config 116 and above Configuration 116 and above Firmware version 3 00 and above A Third generation isolated RS 232 P Ns 5002605 XXX 5002610 XXX 5002447 XXX or Any Remanufactured Part with Config 109 and DP 1028 Any Remanufactured Part with Config 110 and above Configuration 110 and above Firmware version 2 02 and above A Second generation non isolated RS 232 P Ns 5002605 XXX 5002610 XXX 5002447 XXX Configuration between 105 and 108 Firmware versions 2 0 2 1 AN First generation non isolated RS 232 P Ns 50024XX XXX Configuration earlier than 105 Firmware versions 1 00 1 01 INSTALLING THE HFG2 0 lil PRECISION A Hamilton Sundstrand Company 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 e Electronics concepts such as voltage current and switches e Mechanical motion control concepts such as inertia torque velocity distance force Related Publications ActWiz Software Operations Manual p n SD 6010 iv HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 1 INSTALLING THE HFG2 0 1 1 Before Beginning Inspection The HFG2 0 should b
40. c 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 INSTALLING THE HFG2 0 19 PRECISION Hamilton Sundstrand Company 20 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 See Figure 1 13 for a typical analog input connection CONTROLLER 4 20mA OUTPUT HFG2 0 4 20mA INPUT DEMAND BRN Figure 1 13 Typical Analog Input Connection Analog Outputs The analog outputs MOTOR CURRENT and POSITION have a current range of 4 20 mA They are 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 See Figure 1 14 for a typical analog output connection CONTROLLER 4 20mA INPUT HFG2 0 4 20mA OUTPUT POSITION EL MTR CURRENT BLU POSITION RTN W HT YEL 2 MTR CURRENT WHT BLU Figure 1 14 Typical Analog Output Connection Discrete Inputs The discrete inputs are 24 VDC ON High and 0 VDC OFF Low They are electrically isolat
41. e 1 3 Wire Size HFG2 0 Power Harness 17 Table 1 4 Wire List for HFG2 0 System Signal 18 Table 1 5 Computer COM Port Pin Outs 22 Table 1 6 Wire Size for HFG2 0 Signal Harness 23 Table 3 1 Default Configuration For FAULT Alarm 47 Table 3 2 Default Configuration For OVERTEMP Alarm 47 Table 3 3 Fault Configuration For FAULT Alarm AAA 48 Table 3 4 Fault Configuration For OVERTEMP Alarm A 49 Table 3 5 Typical HFG2 0 Setup Parameters With Default Values 51 Table 5 1 Initial Installation Troubleshooting Chalrt 57 Table 5 2 HFG2 0 In Service Troubleshooting Chart 57 Table 5 3 HFG2 0 Electrical Continuity Troubleshooting Chart o8 li HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 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
42. e 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 Examine the wires of the signal and power harnesses for any signs of damage to the wire insulation In the event that any damage is detected contact PECC for instructions about how to proceed A note Retain the 8 original shipping container In the event of future transportation requirements this container will minimize any damage during shipment Recommended Installation Process Users must determine if it is best to couple the HFG2 0 to the load before or after the installation has been tested e Review the general specifications e Mechanically connect the clevis of the HFG2 0 e Mechanically mount the valve body of the HFG2 0 e Mechanically connect the input pipe of the HFG2 0 e Mechanically connect the output pipe of the HFG2 0 e Connect Case Ground of the HFG2 0 to System Ground e Connect the 4 wire Power Harness of the HFG2 0 to the user s power supply or battery e Connect the 17 wire Signal Harness of the HFG2 0 to the user s controller the installation INSTALLING THE HFG2 0 1 PRECISION A Hamilton Sundstrand Company Electrical Noise Guidelines PECC has taken the following measures to reduce electrical noise with the HFG2 0 High voltage wires are rout
43. ed fail safe spring is located between the valve housing and poppet assembly The spring load increases as the valve opens If a power failure occurs the spring causes the poppets to return to the soft seats thereby closing the valve WARNING The soft seats are unidirectional and will leak if the OUTLET is more than 50 psi greater than the INLET PECC recommends that the INLET port pressure always be 2 to the OUTLET port pressure 2 UNDERSTANDING THE HFG2 0 25 PRECISION A Hamilton Sundstrand Company 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 The MCE incorporates analog and discrete inputs and outputs and a serial interface The MCE provides signal conditioning for all external analog and discrete I O as well as internal resolver and thermistor inputs v Note The MCE analog and discrete signal interfaces are electrically isolated The serial communication interface is optically isolated The internally interfaces with brushless motor resolver and thermistors The MCE performs all necessary commutation control and status monitoring for the HF
44. ed separately from low level signals through the use of separate power and signal harnesses An additional measure to reduce electrical noise is to e Ensure that the HFG2 0 is properly grounded as per Section 1 4 of this manual 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 The HFG2 0 enclosure is Canadian Standards Association CSA Type 3 European IP65 CAUTION Solvent water may enter the electronics area during a high pressure wash which can cause decreased performance or failure of the unit 2 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand ompary 1 2 General Specification PARAMETER ETER PARAMETER VALE Power Input 80 160 VDC 120 VDC nominal Typical Transient Current 20 lt 60ms 10 lt 120ms 5 lt 100ms Discrete Inputs RUN and RESET commands Discrete Outputs FAULT amp OVERTEMP alarms Analog Input DEMAND command signal ON Voltage 12 32 VDC 24 VDC nominal 6 5 mA OFF Voltage 1 0 VDC maximum OFF Voltage 32 VDC maximum 150 HA typical Effective ON Resistance 1 1 nominal 21 5 VDC Current 4 to 20 mA 25 mA Maximum Voltage 5 VDC Maximum Internal Impedance 200 Q Analog Outputs Current 4 to 20 mA POSITION amp MTR CURRENT feedback External Load Resistance 300 Maximum Maxi
45. ed up to 500 VAC See Figure 1 15 for a typical discrete input connection CONTROLLER DISCRETE OUTPUT HFG2 0 DISCRETE INPUT GRY PRIN VV TI RESET IWHTGRY Figure 1 15 Typical Discrete Input Command Connection HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company 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 DISCRETE INPUT HFG2 0 DISCRETE OUTPUT FAULT ALARM OVERTEMP ALARM FAULT RIN OVERTEMP RTN WH CONTROLLER DISCRETE INPUT OVERTEMP ALARM WHT BLK ORN BLK AULT ALARM OVERTEMP ALARM Figure 1 16 Typical Discrete Output Alarm Connections RS232 Serial Communications Interface oignal levels for the serial communications input and output are per 5232 standards See Figure 1 17 for a typical RS232 serial interface connection See Table 1 5 for computer COM port pin outs for RS232 COMPUTER COM 1 HFG2 0 RS232 INPUT OUTPUT Figure 1 17 Typical RS232 Serial Interface Connection INSTALLING THE HFG2 0 21 PRECISION A Hamilton Sundstrand Company 22 COM Port COM Port Transmit 10 Receive Rx Ground GND Table 1 5 Computer COM Port Pin Outs WARNING Property Damage Hazard The serial inputs are not electrically isolated
46. eters or uploaded to establish new Set Up parameters A Fault file can also be downloaded also using the ActWiz software Please see the ActWiz software manual for more information CAUTION The HFG2 0 will not hold position when communicating with ActWiz software The return spring causes the poppets to return to the soft seats thereby closing the valve A fault file also can be downloaded when the HFG2 0 is in the Power Up Set Up state by using ActWiz software via the RS232 interface The fault file will provide fault information and possible causes 50 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company PARAMETER DESCRIPTION FACTORY SETTING Part Number Describes part number of actuator model Actuator Type Describes type of actuator Stand Alone Home Controls the direction the actuator will Extend move extending or retracting to find the mechanical stop HOME Span Sets the maximum stroke length 1 0 inches measured from the HOME position Stop Position Sets the signal loss position measured 0 0 inches from the HOME position Interpolation Table sets how Demand signal is interpolated Linear between defined points Pomos C mea Deme mea 0 Maximum Velocity Sets the maximum velocity Sets the maximum force output 1267 Ibf Maximum Homing Velocity Sets the maximum velocity used to find 0 5 in s the HO
47. etwork and to provide the feedback signal to the user The installation of these devices and the final connections to the conduit shall comply with the requirements of the European standards Ground Connection The case of the HFG2 0 features a threaded hole 0 250 20 UNC 2B female thread that is dedicated for the ground connection This hole has been left unpainted and uncoated to ensure a good electrical contact This threaded hole is located on the clevis end of the unit see Figure 1 6 Figure 1 7 or Figure 1 8 Use a screw with a 0 250 20 UNC 2A thread to connect the case of the HFG2 0 to the same ground plane as the user s controller Power Connections 14 The HFG2 0 operates on a 120VDC nominal user provided input voltage which is supplied to the unit through the integral four wire power harness See Table 1 1 for the wire list for the HFG2 0 power harness See Figure 1 9 for the HFG2 0 system power wiring diagram See Figure 1 10 for a typical power connection with a power supply See Figure 1 11 for a typical power connection with a battery WIRE COLOR FUNCTION RED Power WHITE RED Power AUX GREEN Power Return WHITE GREEN Power Return AUX Table 1 1 Wire List for 2 0 Power Harness HFG2 0 USER GUIDE PRECISION Hamilton Sundstrand Company Fower 2 0 Supply FYH 120 VDC MAR ALE man MH NG
48. furbishment Plate CH 2 UNDERSTANDING THE HFG2 0 37 PRECISION A Hamilton Sundstrand Company 38 PRECISION A Hamilton Sundstrand Company INTENTIONALLY BLANK HFG2 0 USER GUIDE PRECISION Hamilton Sundstrand Company 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 The position of the actuator correlates directly to the position of the valve poppets relative to the orifices The Home position of the actuator is the CLOSED position zero position of the valve 3 1 Powering Up When 120 VDC is applied the firmware program in the HFG2 0 will clear all system registers retrieve all necessary operating parameters from the electrically erasable programmable read only memory EEPROM and perform an internal status check This will also happen after RESET command has been received See the flow chart in Figure 3 1 for an overview of this process A uote If the HFG2 0 receives a SET UP command from the ActWiz software via the RS232 interface after these steps the system will transition to the Set Up state This state allows the user to change the Set Up parameters and to download the fault file See Section 3 8 for details CAUTION Always
49. h will open interrupting the circuit with the user s controller The default configuration for the OVERTEMP alarm is Motor OVERTEMP where the circuit will open if the temperature in two or more of the motor winding exceeds 135 C See Table 3 2 for details about the default configuration N In earlier generations of the HFG2 0 the OVERTEMP alarm is dedicated to Motor Over Temp N Z and Electronics Over Temp A N faults If the HFG2 0 detects that the temperature in two or more of the motor windings exceeds 130 C AAA or the electronics temperature exceeds 110 C AA the OVERTEMP circuit will open see Table 3 4 In generation A the Electronics Over Temp fault is assigned to the FAULT alarm If the electronics temperature exceeds 110 C N the FAULT circuit will open see Table 3 3 RS232 Communications The HFG2 0 allows for RS232 serial communication through three wires in the integral 17 wire signal harness The RS232 wires Rx IN Serial Tx OUT and Serial RTN are used to communicate with a user provided computer Serial communication can be used to change the HFG2 0 set up parameters and to retrieve fault diagnostics Contact Precision Engine Controls Corporation to request fault diagnostic software See Section 3 8 for additional details about set up parameters 2 UNDERSTANDING THE HFG2 0 29 PRECISION A Hamilton Sundstrand Company v Note The MCE analog and discrete signal interfaces are electrically isolated
50. he maximum bus voltage specifications This test should be performed at both the minimum and maximum expected operating voltages Also the output capacitance should be carefully positioned so that it is never disconnected from the HFG2 0 power input during any contact or switching operations Recommended Wiring for System Power The recommended wire for connecting to system power is a two conductor shielded cable containing twisted pair wires with individual shields Use a wire size large enough to accommodate the installation and provide a maximum one 1 ohm loop resistance See Table 1 3 below for recommended wire sizes DISTANCE TO RECOMMENDED WIRE SIZE USER POWER Minimum lt 500 ft AWG 10 stranded gt 500 ft Consult Factory Table 1 3 Wire Size for 2 0 Power Harness WARNING Explosion Hazard Do not connect or disconnect while circuit is live For US Group B hazardous locations an explosion proof seal must be placed within 18 inches CAUTION Disconnect all HFG2 0 connections prior to welding INSTALLING THE HFG2 0 17 PRECISION A Hamilton Sundstrand Company 18 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 WIRE COLOR WHITE ORANGE YELLOW WHITE ORANGE BLUE WHITE ORANGE GREEN BLACK WHITE BLACK ORANGE WH
51. ied in the Set Up parameters and has a default value of 500 Ibf When the pre determined motor current limit is reached the HFG2 0 defines this valve position as Home Home is Valve Closed for the HFG2 0 The system will then transition to the Holding Motor Current State See the flow chart in Figure 3 1 for an overview of this process The DEMAND current determines subsequent positioning of the actuator and thus the valve within its span once the Home position has been established oee Section 3 8 for additional information about Set Up parameters 3 3 Holding Motor Current State In the Holding Motor Current state the actuator applies a constant Holding Force This feature allows the Home position to thermally expand or contract without damaging the HFG2 0 This Holding Force is specified in the Set Up parameters and has a default value of 500 Ibf The system is in the Holding Motor Current state immediately after Homing The system will also move into this state when the DEMAND signal is gt 2mA and lt 4 1mA See the flow chart in Figure 3 1 40 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company Figure 3 1 HFG2 0 Basic Operation Flow Chart CH 3 OPERATING THE HFG2 0 41 PRECISION A Hamilton Sundstrand Company 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 fo
52. istance CH 4 TROUBLESHOOTING THE HFG2 0 55 PRECISION A Hamilton Sundstrand Company Symptom Probable Causes Corrective Action Valve Inoperative Power Wires not connected Ensure RED and GREEN wires correctly connected to FAULT alarm valve No or low 120 VDC power Ensure 120 VDC Primary System Power at valve Valve No RUN or position command Ensure VIOLET and WHITE VIOLET wires correctly NO FAULT alarm connected to valve Ensure 24 VDC RUN and position command at valve Actuator moves toward Intermittent RUN command Ensure consistent 24 VDC RUN command and fuel HOME then stops demand signal Homing Force Too Low Ensure position command at valve No position demand Actuator moves toward Intermittent RESET command Ensure GRAY and WHITE GRAY wires correctly HOME intermittently connected to Actuator Ensure consistent 24 VDC RESET command Actuator finds HOME then No fuel demand signal Ensure BROWN and WHITE BROWN wires correctly moves to STOP position connected to Actuator Ensure fuel demand 2 0 mA at Actuator Valve does not track fuel No fuel demand signal or RUN Ensure BROWN and WHITE BROWN wires correctly demand command connected to valve Ensure valve demand 4 1 mA at valve Ensure RUN command present at valve Valve does not hold Varying fuel demand signal Ensure stable fuel demand at the actuator position oscillates No or low 120 VDC power Ensure 120 VDC at valve or dithers No valve feedback Valve feedbac
53. k wires not Ensure YELLOW and WHITE YELLOW wires correctly connected connected No or low 120 VDC power Ensure 120 VDC at valve Self protective valve auto shut Upload Fault File check for motor windings over down temperature faults Check for valve contamination No RUN command Ensure RUN command present at valve No motor current feedback Motor current wires not Ensure BLUE and WHITE BLUE wires correctly connected connected No or low 120 VDC power Ensure 120 VDC at valve No RUN command Ensure RUN command present at valve Valve Operative FAULT FAULT wiring incorrect Ensure ORANGE and WHITE ORANGE wires alarm active correctly connected to Actuator Internal FAULT Upload Fault File to identify source of fault Valve Operative OVER OVERTEMP wiring incorrect Ensure BLACK and WHITE BLACK wires correctly TEMP alarm active connected to valve Electronics or motor winding Reduce External ambient temperature temperature out of range Valve jammed Check for valve contamination Valve leaks when closed Poppet assembly fouled Stroke valve OPEN and clear foul at orifice Valve installed backwards Ensure supply is connected to valve IN port 56 HFG2 0 USER GUIDE PRECISION A Hamilton Sundstrand Company Symptom Probable Causes Corrective Action RS232 Interface Inoperative Incorrect wiring Ensure WHITE ORANGE YELLOW WHITE ORANGE BLUE WHITE ORANGE GREEN wires correctly connected to valve and laptop PC No or low 120 VDC power Ensure 1
54. lts that can be detected by the HFG2 0 See Section 3 7 and Table 3 1 N Table 3 2 N Table 3 3 AAA and Table 3 4 A AN for additional details about system faults Driver over current The maximum current output limit is 25 amps If the is outputting its maximum current for ten 10 seconds the MCE signals a fault If MCE maximum current drop below the maximum current the fault signal is cleared Tracking error The HFG2 0 position should continuously track demand Should the position versus demand vary more than one motor revolution 0 20 inches for more than ten 10 seconds the MCE signals a fault If the position returns to within one motor revolution the fault signal is cleared CH 4 TROUBLESHOOTING THE HFG2 0 59 PRECISION Hamilton Sundstrand Company 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 The RDC chip has on board health monitoring If the RDC detect an internal tracking error a signal is sent to the MCE Upon receipt the MCE signals a fault This fault does not clear without RESET command Unregulated Voltage Low
55. mum Common Mode Voltage 200 VDC User to 120 VDC Return less serial interface Performance Maximum Operating Pressure Proof Pressure Minimum Controllable Flow Natural Gas Maximum Controllable Flow Step Response 1096 to 9096 Flow Accuracy Mean Time Before Unscheduled Removal Life Cycles Environmental Temperature Operating Ambient Temperature Operating Fuel Temperature Storage Environmental Rating EMC Vibration All performance values are based on use with HFG2 0 in default configuration Any changes to HFG2 0 firmware settings to change stroke profile will alter performance values 500 psig 2000 psig 15 pph configuration dependent 30 000 pph configuration dependent 100 ms 5 of flow point typical 30 000 Hours 32 000 Minimum 40 C 40 F to 93 C 200 F 40 C 40 F to 1252 C 257 40 C 40 F to 1252 C 257 F Rated to CSA Type 3 and European IP65 Sealed against dust protected against water Meets EN 50081 2 and EN50082 2 for DC powered industrial equipment Meets Mil Std 810E Category 4 5 2000 Hz INSTALLING THE HFG2 0 3 PRECISION A Hamilton Sundstrand Company Certifications North American Certifications CSA Class Div 1 Group B C D T4 European Directive Compliance CE Mark x 11 26 EEx IIB H gt T4 97 23 EC Pressure Equipment Directive PED 94 9 EC Potentially Explosive Atmospheres ATEX 02 6051 98 3
56. r 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 lt 2 mA signal loss at any time after the actuator has completed Homing It will also move to the Stop position if the RUN command is removed during any of the running modes See the flow chart in Figure 3 1 3 5 Controlling Motion 42 Home Position Once the Home position has been established the DEMAND current determines subsequent positioning of the actuator and thus the valve within its span The valve will track the DEMAND signal as long as DEMAND 2 4 1 mA and RUN is ON and will apply up to the maximum force to reach this DEMAND position See Figure 3 2 This is defined as the RUN state and it is the normal operating mode for the HFG2 0 The actuator firmware program will remain in this state as long as the demand is greater than 4 1 mA A If RUN command is removed or position DEMAND lt 2 mA the actuator will go to the STOP position The Home position correlates to a DEMAND signal of 4 mA The Home position is determined after Power Up or after the HFG2 0 has been reset Dead Band While the Home position correlates to a DEMAND signal of 4 mA the actuator will only move for DEMAND signals 2 4 1 mA The DEMAND signal range between 4 0 mA and 4 1 mA is therefore considered a Dead Band See Figure 3 3 Once a DEMAND signal gt 4 1 mA is detected the actuator will move to
57. s burn injury CH 3 OPERATING THE HFG2 0 49 PRECISION A Hamilton Sundstrand Company 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 See Table 3 5 for typical Set Up parameters Users can change the Set Up parameters to better suit their specific applications These parameters are uploaded to the HFG2 0 via the RS232 interface using PECC s ActWiz software The Set Up parameters can only be accessed when the HFG2 0 is in the Power Up Set Up state See the Basic Operation Flow Chart in Figure 3 1 and the Power Up Set Up State section below for details Contact PECC for a copy of ActWiz software See the ActWiz Software Manual for further details Power Up Set Up State HFG2 0 is in Power Up Set Up state immediately after the HFG2 0 has been powered up or reset This is after the system registers have been cleared and the Set Up parameters have been reloaded but before the Homing process has begun RUN command OFF This is the only state in which the user can communicate with HFG2 0 via the 5232 interface In this state a set up file can be downloaded to view the current Set Up param
58. 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 The current level of the DEMAND signal is correlated to the position of the valve within its range The minimum Demand signal of 4 0 mA is correlated to the CLOSED Home position The maximum Demand signal of 20 mA is correlated to the OPEN maximum flow position Feedback Signals The HFG2 0 provides two two wire feedback signals via the integral 17 wire signal harness Refer to Figure 1 14 for typical connections Refer to the General Specification Summary Table in Section 1 2 for feedback specification values Position Feedback The HFG2 0 provides analog valve position feedback to the user This internally generated feedback signal is proportional to the valve position A signal level of 4 mA represents that the valve is at its CLOSED Home position while a signal level of 20 mA represents that the valve is at its maximum span Motor Current Feedback The HFG2 0 provides motor current feedback This internally generated feedback signal is proportional to actuator load A signal level of 4 mA represents no load on the actuator while a signal level of 20 mA is the maximum load CH 2 UNDERSTANDING THE HFG2 0 27 PRECISION A Hamilton Sundstrand Company i IL ERG THERE toro iom Poser Polarity 80 85 VD GULLY Power _ Power Interface Brushless
59. to the assembly Pipe Connections The standard pipe connection for the HFG2 0 is per SAE J518 32 2 inch code 61 The valve bodies contain locking helical inserts Contact Precision Engine Controls for other connection options A note To maintain flow control accuracy ten 10 pipe diameters 15 inches straight length minimum is recommended upstream and downstream Flange Bolts Precision Engine Controls Corporation recommends SAE Grade 5 or better flange bolts Torque to 650 800 in lb CAUTION Do not over torque fittings Over torque may result in stripped threads and or helical insert damage Drain Plug PECC recommends 60 65 in Ib of torque for the drain plug see Figure 1 6 View B B A note The one piece housing version of the HFG2 0 does not have a drain hole INSTALLING THE HFG2 0 7 PRECISION A Hamilton Sundstrand Company 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 2375 0 ea 2s 1 Z e 598 12117 Lx X 7 98 202 27 77771 182 46 21 NAK 50 740 6 8 60 218 4 10 48 258 7 4 50 15 UNC 2B 2 7 41 00 725 47 4 75 20 71 22 40 30 80 SAC 548 COJE 61 4 NE
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