Instruction/ maintenance manual of the product HFG2.0 Hamilton Sundstrand Company
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User Manual HFG2.0 Gas Fuel Metering Valve SD-6009 Rev. 6 August 2008 PRECISION ENGINE CONTROLS CORPORATION.
This manual provides installation , maintenance , and operating instructio ns for the HFG2.0 Gas Fuel Metering Valve. Every attempt has been made to provide sufficient information in this manual for the proper operation and pr eventive maintenance of the valve.
T ABLE OF CONTENTS Purpose of This Guide ............................................................................................................................... .... iii Product Identification ..................................................
ii HFG2.0 USER GUIDE Figure 1-11 . Typical Po wer Connection With Battery ....................................................... 15 Figure 1-12: HFG2.0 Sy stem Signal Wiri ng Diagram ...................................................... 19 Figure 1-13 .
Purpose of This Guide This publication is designed to help the user insta ll, operate, maintain and troubleshoot the HFG2.0 Gas Fuel Metering Valve. Product Identification Most of the information in this manua l is applicable to all generat ions of the product.
iv HFG2.0 USER GUIDE What the User Should Know To install, operate a nd troubleshoot th e HFG2.0, it is necessary for the user to have a fundament al understanding of: • Electronics concepts, such a.
1 INST ALLING THE HFG2.0 1.1 Before Beginning Inspection The HFG2.0 should be inspected immediately after unpa cking. Check for dings or dents or any other obvious signs of damage. Remove the protective caps from the connectors and check for any bent pins or damage to the threads of t he connectors.
2 HFG2.0 USER GUIDE Electrical Noise Guidelines PECC has taken the follow ing measures to reduce electrical noise wit h the HFG2.0: • High-voltage wires are routed separately from low-level signals through the use of separ ate power and signal harnesses.
1.2 General S pecification Summary PARAMETER VALUE Power Input Voltage Range 80-160 VDC; 120 VDC nominal Maximum Current 20 A Typical Transient Current +20A < 60ms; +1 0A < 120ms; -5A < 100ms Typical Continuous Current < 1A Inputs and Outputs Discrete Inputs RUN and RESET commands ON Voltage: 12 – 32 VDC, +24 VDC nominal @ 6.
4 HFG2.0 USER GUIDE Certifications North American Certifications CSA Class I, Div 1, Group B, C, D; T4 European Directive Compliance (CE Mark) EEx d, IIB+H 2 ; T4 97/23/EC Pressure Equipment Directive.
Figure 1-1. Typical HFG2. 0 Gas F uel System Installation Figure 1-2. Alternate HFG2.0 Gas Fuel System Instal lation Dimensions Figure 1-3 and Figure 1 -4 show external dimensio ns for the 3-piece housing and 1-piece housing version s of the HFG2.0, respectively.
6 HFG2.0 USER GUIDE The HFG2.0 includes four (4) 0. 50-24 UNC-2B mounting holes with stainless steel heli- coil inserts for securing the valve body. The mounting holes on the standard ver sion of the HFG2.0 are lo cated on the opposite side from the electrical connect ors.
WARNING Explosion Hazard – Do not remove the clevis. Removing the clevis violates the warranty . Care should also be taken when rot ating the clevis or indexi ng the screw pattern to avoid scratchin g the flame path or introdu cing particulates to the assembly .
8 HFG2.0 USER GUIDE Vent Port The gas leakage rate through th e vent port is less th an 200 cm 3 /hr (air or N 2 as t est flow). The vent port fe atures a 1/8-NPT fitting. See Fig ure 1-4. Consult local installation codes to determine whether and h ow to connect this port.
Figure 1-4. HFG2.0 Dimensions, 1-Piece Housing INSTALLING THE HFG2.0 9.
10 HFG2.0 USER GUIDE Figure 1-5. HFG2.0 Mounting Orientations.
Figure 1-6. HFG2.0 Mounting Provisions, 3-Piece Hou sing (Standard Mounting Orient ation Shown) INSTALLING THE HFG2.0 11.
12 HFG2.0 USER GUIDE Figure 1-7. HFG2.0 Mounting Provisions, 1-Piece Hou sing (Standard Mounting Orient ation Shown).
Figure 1-8. HFG2.0 Mounting Provisions, 1-Piece Hou sing (Reversed Mounting O rien tation Shown) INSTALLING THE HFG2.0 13.
14 HFG2.0 USER GUIDE 1.4 Electrical Connections The HFG2.0 is suitable for use in hazardous lo cations. See the General Specification Summary in Section 1 .2 for certifica tions. Ensure compliance with the factory recommendations, an d that wiring is in accordance with local require ments.
Figure 1-9: HFG2.0 System Power Wiring Diagram Figure 1-10. Typical Powe r Con nection With Power Suppl y Figure 1-11. Typical Power Con ne ction With Battery WARNING - Shock Hazard Connect both the 120 V DC power and auxiliary wires.
16 HFG2.0 USER GUIDE Note: A battery s ystem is recommen ded for highest reliabili ty. Note: If a 120 VDC po wer supply is used rathe r than a battery, ensure an output capacit ance of at least 12,00 0 µF, which can both sink and s ource electric current.
Therefore, it is not possible to correctly state a sing le capacitance value that should be placed on the bus. It may require no added bus capacitan ce or hundreds of thousands of microfarads of capacitance.
18 HFG2.0 USER GUIDE Signal Connections Signals are sent between the HFG2.0 and the user’s controller t hrough the integral 17-wire signal harness. See Table 1-4 f or the wire list for this harness. See Figure 1- 12 for the system signa l wiring diagram.
Figure 1-12: HFG2.0 System Signal Wiring Di agram Note: For proper operati on of the controller, the voltage be tween the control inputs and th e negative terminal of the power supply should be belo w 200 VDC. Note: The Serial Re turn is internally c onnected to the 120 VDC input Return.
20 HFG2.0 USER GUIDE Analog In puts The analog input, DEMAND, has a current ra nge of 4 - 20 mA. It is electrically isolated up to 500 VAC from the enclosure, 120 VDC power, digital I/O, and serial interf ace. The analog inter faces are not isolated from each other.
Discrete Outputs The discrete outputs are + 24 VDC. They are electrically isolated up to 500 VAC. See Figure 1-16 for a typical discrete output alarm connectio n.
22 HFG2.0 USER GUIDE FUNCTION Standard 9-Pin COM Port Standard 25-Pin COM Port Transmit (Tx). Pin 3 Pin 2 Receive (Rx) Pin 2 Pin 3 Ground (GND) Pin 5 Pin 7 Table 1-5. Com puter COM Port Pin Out s WARNING Property Damage Hazard – The serial inputs are not electri cally isolated .
Recommended Wir ing for Sy stem Signa ls The recommended wiring is a 17-con ductor shielded cab le containing twisted-pair wires with in dividual shields. Use a wire size large enough to accommodate the installation and provide a maximum fifty (50) ohm loop resistance.
24 HFG2.0 USER GUIDE I NTENTIONALLY B LANK.
2 UNDERST ANDING THE HFG2.0 2.1 System Description The HFG2.0 is an electrically ope rated gas fuel-metering valve that requires only 120 VDC po wer, an analog fuel demand signal, an d a discrete RUN command to achieve ba sic operational capability. No pneumatic or hydraulic power is requir ed.
26 HFG2.0 USER GUIDE 2.2 Electrical Description The electric actuator in th e HFG2.0 incorporates digital motor control electronics (MCE). The MCE contain anal og to digital converters, a digital signal processor (DSP), application specific integr ated circuit (ASIC) and power supplies.
during the RESET command. To reset the HFG2.0, +24 VDC must be applied across the RESET wires for at least 0.5 seconds in o rder to reset the controller and actua tor. DEMAND Signal The DEMAND signal is a user-provided analog inp ut that is used to control the position of the valve.
28 HFG2.0 USER GUIDE Figure 2-1. HFG2.0 Electronics System Block Diag ram.
Alarms The HFG2.0 provides two two-wire alarm signa ls via the integral 17-wire signal harness. The discrete alarm outputs are solid-state switches which are normally closed. The user’s controller provides +24 VDC to complete the circuit. Refer to Figur e 1-16 for typical connections.
30 HFG2.0 USER GUIDE Note: The MCE an alog and discrete signa l interfaces are electrically isolated. T he serial communicati on interface is optically isolated 2.3 Mechanical Description The HFG2.0 consists of two main par ts, an actuator and a valve assembly.
monitor winding temperatures. The m otor electrical power and t hermistor wires pass through a cond uit into the electronics h ousing. Motor Rotor The motor rotor is locked to the ball screw shaft via a straigh t key.
32 HFG2.0 USER GUIDE Extension Rod and Bearings The extension rod is threa ded on the ball nut. A s the ball nut transla tes, the extension rod moves in and out of the HFG2.
Orifice Assembly The orifice assembly cont ains a set of poppets an d orifice plates. Fuel flow is metered between the INLET po rt chamber and OUTLET port chamber in proportion t o the poppet position a nd resultant flow area. The poppet assembly is conne cted to the extension rod o f the actuator.
34 HFG2.0 USER GUIDE Figure 2-2. HFG2.0 Cut-Away View – Actuator Main Housing Assem bly.
Figure 2-3. HFG2.0 Cut-Away View (Partial) CH. 2: UNDERSTANDING THE HFG2.0 35.
36 HFG2.0 USER GUIDE 2.4 Identification Plate A product identificatio n plate is attached to the HFG2.0 housing assembly. Figure 2-4 shows a typical identification plate. The identification plate lists model designation, product part number, revision and unit serial number.
Figure 2-5. Typical Refurbishment Plate CH. 2: UNDERSTANDING THE HFG2.0 37.
38 HFG2.0 USER GUIDE I NTENTIONALLY B LANK.
3 OPERA TING THE HFG2.0 This section refers to the position of the actuator when describing operation of the HFG2.0 v alve. The end of the actuator exten sion rod is connected to the poppet assembly of the valve. The linear mot ion of the actuator, both extension and ret raction, is directly translated to t he poppet assembly.
40 HFG2.0 USER GUIDE this point, the HFG2.0 has no info rmation about the position of the actuator extension shaft. When the HFG2.0 receives the RUN comm and, it will initiate motion in the homing direction. The default homing direction f or the HFG2.
Figure 3-1. HFG2.0 Basic Operation Flow Chart CH. 3: OPERATING THE HFG2.0 41.
42 HFG2.0 USER GUIDE 3.4 Moving to S top Position The Stop position is a fail-safe position that may be set anywhere between Home (zero position, Valve Close d) and maximum span (maximum flow). The default value fo r Stop position is 0.0 inche s, as defined in the Set-Up parameters.
Full Span Position (Maximum Flow) The Full Span (Maximum Flow) positi o n correlates t o a DEMAND signal of 20 mA. The maximum Span possible for the HFG2.0 is 1.0 inches due to the configuration of the valve assembly. The maximum Span possible for the actuator used in the HFG2.
44 HFG2.0 USER GUIDE A non-linear interpolation table can be created to define positioning at 16 discrete current levels in the DEMAND signal range , but only during Set Up using the ActWiz Softw are. See the Section 3.8 for additional details about Set Up parameters.
3.7 Monitoring System Health The firmware program continuously monitors syste m health while the HFG2.0 is powered. If any of the healt h parameters are out of the normal operating range, t he MCE outputs a discrete fau lt alarm to the user’s controller.
46 HFG2.0 USER GUIDE See Table 3-4 for a list of Over Temp conditions represented by t he OVERTEMP alarm in earlier generations of th e HFG. Fault File The HFG2.0 firmware also captures the fault data in the EEPROM. If the HFG2.0 is operational, a fault fi le can be downloaded using Act Wiz software via the RS232 int erface.
Fault Type Low Alarm High Alarm Fault Enable Persist Time Auto Reset Output Driver Overcurrent N/A 1000 lbf Yes 10 Sec Yes Yes Tracking Error N/A 3.33 % Yes 10 Sec Yes Yes Position Demand 3.5 mA 20.5 mA No 1 Sec No No RDC Failure N/A N/A Yes N/A No Yes +14 Volts 12.
48 HFG2.0 USER GUIDE Fault Alarm Type Persist Time Fault Action Driver Over Current 10 Sec 1 Sec Driver current > Max F orce equivalent current, Fault. Driver current > Max F orce equivalent current, Fault. If persists for 1 Min., Shutdown Driver current > 18 Amps, Fault.
Fault Type Persist Time Fault Action Motor 10 Sec 1 Sec Motor temp > 130° C, Fault. . If fault exists and Motor temp > 135° C for 10 Sec, shutdown. Motor temp > 130° C, Fault . If fault exists and Motor temp > 130° C for 60 Sec, shutdown.
50 HFG2.0 USER GUIDE 3.8 Changing Set-Up Parameters The HFG2.0 uses a number of variables to define its functionality. These variables are called Set-U p parameters and they are sto red in the EEPROM in the HFG2.0. Default values for these variables are loaded into the EEPROM at the PECC factor y.
PARAMETER DESCRIPTION FACTORY SETTING Part Number Describes pa rt number of a ctuator model Per Drawing Actuator Type Describes type of actuator Stand Alone Command Source Sets type of command si gnal.
52 HFG2.0 USER GUIDE I NTENTIONALLY B LANK.
4 MAINT AINING THE HFG2.0 Under normal operation, the HFG2.0 requires no formal mainten ance program. Regularly scheduled inspections should be p erformed to check for: • any damage to wire insulati.
54 HFG2.0 USER GUIDE I NTENTIONALLY B LANK.
5 TROUBLESHOOTING This section provides troubleshooti ng information for the HFG2.0. You can isolate most ele ctrical faults by using an exte rnal oscilloscope and digital voltmeter (DVM) and computer with d iagnostic software.
56 HFG2.0 USER GUIDE Symptom Probable Causes Corrective Action Valve Inoperative - FAULT alarm Power Wires not connected No or low 120 VDC power Ensure RED and GREEN wires correctly connected to valve.
Symptom Probable Causes Corrective Action RS232 Int erface Inop erative Incorrect wiring No or low 120 VDC power COM1 not connecte d RESET or RUN co mmand is ON Ensure WHITE/ORANGE/YELLOW, WHITE/ORANGE/BLUE, WHITE/ORANGE/GREEN wires correctly connected to valve and laptop PC.
58 HFG2.0 USER GUIDE Function Actuator Wire Colors Resistance Value DEMAND BRN and WH T/BRN 225 Ω RUN VIO and WHT/VIO 4.7 K Ω RESET GRY and WHT/GRY 4.
5.1 F AUL T File The FAULT and OVERTEMP alarms are discrete output s from the HFG2.0. The FAULT and OVERTEMP alarm circuits are closed in the normal operating condit ion. If the HFG2.0 de tects a fault, the alar m circuit for that fault opens, and t he user-provided controller should dete ct the open circuit.
60 HFG2.0 USER GUIDE Watchdog expired The MCE watchdog timer continuously monitors the firmware program. Should the MCE firmware program st op functioning, or attempt to acce ss an illegal address, the MCE sign als a fault. This fault does not clear without RESET command.
APPENDIX A: DECOMMISSIONING & DISPOSAL This section contains re commended HFG2.0 decommissioning and disposal practices. It is for permanent removal or replacement of the installed product, with no intentions of rework, overhaul, or to be used as spares.
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APPENDIX B: GLOSSAR Y Term Definition RUN Command A discrete 24 VDC signal that enabl es the HFG2.0 actu ator and valve to move. RESET Command A discrete 24 VD C signal that causes the HFG2.0 internal program (firmware) to jump to the be ginning. Controller A user-provided computer that exe cutes commands t o the HFG2.
I NTENTIONALLY B LANK 64 HFG2.0 USER GUIDE.
An important point after buying a device Hamilton Sundstrand Company HFG2.0 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Hamilton Sundstrand Company HFG2.0 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hamilton Sundstrand Company HFG2.0 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hamilton Sundstrand Company HFG2.0 you will learn all the available features of the product, as well as information on its operation. The information that you get Hamilton Sundstrand Company HFG2.0 will certainly help you make a decision on the purchase.
If you already are a holder of Hamilton Sundstrand Company HFG2.0, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Hamilton Sundstrand Company HFG2.0.
However, one of the most important roles played by the user manual is to help in solving problems with Hamilton Sundstrand Company HFG2.0. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hamilton Sundstrand Company HFG2.0 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
