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SD-6011 Rev 5
September 2009
This manual provides installation, maintenance, and operating instructions for the XVG/eXVG Series of Gas Fuel Metering Valves. Every attempt has been made to provide sufficient information in this manual for the proper operation and preventive maintenance of the gas fuel-metering valve. Read this manual in its entirety to fully understand the system. Operating the XVG/eXVG Gas Fuel Metering Valve in accordance with instructions herein ensures long term and reliable operation. If you need additional information, please contact: Marketing Department Precision Engine Controls Corporation 11661 Sorrento Valley Road San Diego, California 92121 (858) 792-3217 (800) 200-4404 Fax: (858) 792-3200 E-mail: peccntl@precisioneng.com
TABLE OF CONTENTS
Purpose of This Guide ................................................................................................................................... iv What the User Should Know ......................................................................................................................... iv Related Publications....................................................................................................................................... iv 1 INSTALLING THE XVG/eXVG .................................................................................................................. 1 1.1 Before Beginning..................................................................................................................................... 1 1.2 General Specification Summary............................................................................................................. 3 1.3 Mechanical Installation............................................................................................................................ 4 1.4 Electrical Connections............................................................................................................................. 11 2 UNDERSTANDING THE XVG/eXVG ....................................................................................................... 27 2.1 System Description ................................................................................................................................. 27 2.2 Versions of the XVG/eXVG .................................................................................................................... 28 2.3 Operating Modes of XVG/eXVG ............................................................................................................ 37 2.4 Mechanical Functional Description ........................................................................................................ 38 2.5 Electrical Functional Description ............................................................................................................ 41 2.6 Identification Plate ................................................................................................................................... 43 3 OPERATING THE XVG/eXVG .................................................................................................................. 47 3.1 Performance Factors............................................................................................................................... 47 3.2 Operating Modes..................................................................................................................................... 49 3.3 Feedback................................................................................................................................................. 53 3.4 Monitoring System Health....................................................................................................................... 55 4 MAINTAINING THE XVG/eXVG................................................................................................................ 58 4.1 Preventive Maintenance ......................................................................................................................... 58 4.2 Corrective Maintenance.......................................................................................................................... 60 4.3 Calibration................................................................................................................................................ 65 4.4 Refurbishment ......................................................................................................................................... 65 5 TROUBLESHOOTING THE XVG/eXVG .................................................................................................. 66 5.1 Electrical Troubleshooting....................................................................................................................... 66 5.2 Retrieving The Fault File......................................................................................................................... 67 5.3 Fault Diagnosis........................................................................................................................................ 68 APPENDIX A: DECOMMISSIONING & DISPOSAL ...................................................................................... 75
PREFACE
LIST OF FIGURES
Figure 1-1. Typical XVG/eXVG Gas Fuel System Installation ...........................................5 Figure 1-2. Alternate XVG/eXVG Gas Fuel System Installation ........................................5 Figure 1-3. XVG Dimensions ...............................................................................................7 Figure 1-4. eXVG Dimensions .............................................................................................7 Figure 1-5. XVG/eXVG Dimensions with Harness as Electrical Interface (XVG shown) .8 Figure 1-6. XVG Mounting Provisions .................................................................................9 Figure 1-7. eXVG Mounting Provisions ...............................................................................9 Figure 1-8. Wire Harness Connector for XVG/eXVG .......................................................11 Figure 1-9. Terminal Blocks for XVG/eXVG......................................................................12 Figure 1-10. Recommended Type of Explosion-Proof Connector (with wires shown)...13 Figure 1-11. Ground Connections for XVG/eXVG............................................................14 Figure 1-12. Power Connection to Solenoid for XVG/eXVG............................................15 Figure 1-13. Power Connection to Electronics for XVG/eXVG ........................................16 Figure 1-14. Typical Analog Input Current Connection ....................................................18 Figure 1-15. Typical Analog Input Voltage Connection ....................................................18 Figure 1-16. Typical Analog Output Current Connection .................................................19 Figure 1-17. Typical Analog Output Voltage Connection .................................................19 Figure 1-18. Typical Discrete Input Command Connection .............................................20 Figure 1-19. Typical Discrete Output Alarm Connection ..................................................20 Figure 1-20. Typical RS232 Serial Interface Connection .................................................21 Figure 1-21. Typical RS232 Serial Interface Connection .................................................22 Figure 1-22. Wiring Shield Connections............................................................................25 Figure 2-1. Cross-sectional view of XVG/eXVG. ..............................................................28 Figure 2-2. Dynamic seal and scraper of XVG/eXVG. .....................................................29 Figure 2-3. Product Definition Number Details (sample)..................................................31 Figure 2-4. Exploded View of the XVG/eXVG...................................................................40 Figure 2-5. Partial Cutaway View of Breather Vent ..........................................................40 Figure 2-6. XVG/eXVG Electronics System Block Diagram ............................................42 Figure 2-7. Typical Identification Plate for XVG, p/n 5002800-001 or -002.....................44 Figure 2-8. Typical Identification Plate for eXVG, p/n 5002800-003 or -004...................44 Figure 2-9. Typical Identification Plate for XVG, p/n 5002801-001 or -002.....................45 Figure 2-10. Typical Identification Plate for eXVG, p/n 5002801-003 or -004.................45 Figure 3-1. Stroke vs. Fuel Demand Curve.......................................................................50 Figure 3-2. Flow Rate vs. Fuel Demand Curve.................................................................52 Figure 3-3. Flow Rate vs. Outlet Pressure Curve (example) ..........................................54
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Figure 4-1. XVG Orifice Plate Removal.............................................................................62 Figure 4-2. eXVG Orifice Plate Removal...........................................................................62 Figure 4-3. XVG Orifice Plate.............................................................................................64 Figure 4-4. eXVG Orifice Plate...........................................................................................64
LIST OF TABLES
Table 1-1. Connection List for XVG/eXVG Solenoid Power ............................................15 Table 1-2. Connection List for XVG/eXVG Electronics Power.........................................15 Table 1-3. Power Supply Requirements............................................................................16 Table 1-4. Signal Connections for XVG/eXVG, p/n 5002800-00x...................................17 Table 1-5. Signal Connections for XVG/eXVG, p/n 5002801-00x...................................17 Table 1-6. Computer COM Port Pin Outs .........................................................................21 Table 1-7. Computer COM Port Pin Outs .........................................................................22 Table 1-8. Recommended Wire Size for Harness............................................................23 Table 2-1. Part Numbers for XVG/eXVG ..........................................................................29 Table 2-2. Model Numbers and Types..............................................................................30 Table 2-3. Operation Mode Configuration.........................................................................31 Table 2-4. Command (AICH0) Signal Configuration ........................................................32 Table 2-5. Analog Output Parameter Channel Configuration ..........................................33 Table 2-6. Analog Output Signal Configuration ................................................................33 Table 2-7. Gas Constants Configuration ...........................................................................34 Table 2-8. Max Flow Configuration....................................................................................35 Table 2-9. Calibration Curve ..............................................................................................35 Table 2-10. Electrical Interface...........................................................................................36 Table 2-11. Flange Interface ..............................................................................................36 Table 3-1. Command (AICH0) Signal Configurations ......................................................47 Table 3-2. Command Signal Percentage Values .............................................................48 Table 3-3. Maximum Flow Area for XVG/eXVG ...............................................................49 Table 3-4. Feedback (AOCH0 or AOCH1) Signal Configurations...................................54 Table 3-5. Feedback Parameter Configuration.................................................................55 Table 5-1. XVG/eXVG Expected Circuit Impedance ........................................................67 Table 5-2. XVG/eXVG Initial Installation Troubleshooting Chart......................................69 Table 5-3. XVG/eXVG In-Service Troubleshooting Chart................................................70 Table 5-4. System Health Parameters and Limits ............................................................72
PREFACE
iii
Related Publications
XView Software Operation Manual (SD-6014)
IV
Note: Retain the metering valves original shipping container. In the event of future transportation requirements, this container will minimize any damage during shipment.
An additional measure to reduce electrical noise is to: Ensure that the XVG/eXVG is properly grounded, as per Section 1.4, Figure 1-11 of this manual.
Environmental Considerations
The XVG/eXVG operates satisfactorily with an ambient air temperature of -40 C (-40 F) to +93 C (+200 F). The XVG/eXVG enclosure is Canadian Standards Association (CSA) Type 4, European IP56.
VALUE
Inputs and Outputs Analog Inputs Current: 4 to 20 mA; 40 mA Maximum Voltage: 0 to 5 VDC; 8 VDC Maximum Input Impedance: 246 in Current Mode, 16.7k in Voltage Mode Current: 4 to 20 mA Voltage: 0 to 5 VDC Load Resistance: 300 Max in Current Mode, 250 Min in Voltage Mode ON Voltage: ON Current: OFF Voltage: OFF Current: OFF Voltage: OFF Resistance: ON Resistance: ON Voltage: 12 32 VDC, +24 VDC Nominal 1.5 mA Nominal @ 24 VDC 3.5 VDC, Maximum 0.75 mA, Maximum 32 VDC, Maximum 200,000 Minimum 900 to 1100 32 VDC Maximum
Analog Outputs
Discrete Inputs
Discrete Outputs Maximum Common Mode Voltage Communication Hardware Software Protocol Baud Rate (bps) Performance Maximum Operating Pressure Proof Pressure Minimum Delta P Min. Controllable Flow (Natural Gas @ 59F) Max. Controllable Flow (Natural Gas @ 59F under sonic flow conditions, Pin >1.9 Pout) Step Response (10% to 90%) Flow Accuracy Mean Time Before Failure Environmental Temperature, Operating Ambient Temperature, Operating Fuel Temperature, Storage
0 psid (stroke mode), 20 psid (flow control mode) 15,000 lbm /hour 20,000 lbm /hour
-40 C (-40 F) to +93 C (+200 F) -20 C (-4 F) to +93 C (+200 F) -40 C (-40 F) to +125 C (+257 F)
Rated to NEMA 4 and European IP56 Meets Mil-Std-810F, 95% Relative Humidity (Non-Condensing) Meets Mil-Std-810F, Vibration Category 22 (5 2000 Hz) Meets Mil-Std-810F, Functional Shock, 20g peak, 11 ms duration Meets Mil-Std-810F, Transit Drop
Certifications North American Certifications European Directive Compliance (CE Mark) II2G EEx d, IIB+H2; T4 97/23/EC Pressure Equipment Directive (PED) 94/9/EC Potentially Explosive Atmospheres (ATEX) KEMA 04ATEX2326 98/37/EC Machinery Directive 89/336/EEC Electromagnetic Compatibility Directive (EMC) Group 1 Class A EN 50081-2 Emission EN 61000-6-25 Immunity Materials Housing Seals Dimensions 6061-T6 Anodized Aluminum 316 Stainless Steel (Optional) PTFE and Viton XVG: eXVG: XVG: eXVG:
CSA (Canada and US) Class I, Div 1, Group B, C, D; T4. File # 171042
9.08 in x 5.80 in x 6.75 in 9.08 in x 7.70 in x 6.75 in 36 lbs. Max (Aluminum), ~74 lbs. (Stainless Steel) 38 lbs. Max (Aluminum), ~82 lbs. (Stainless Steel)
Weight
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.
Dimensions
Figure 1-3 and Figure 1-4 show external dimensions for the XVG and eXVG, respectively.
Mounting Considerations
The XVG/eXVG includes four (4) 5/16-24 UNF-3B mounting holes with stainless steel heli-coil inserts for securing the controller enclosure. See Figure 1-6 and Figure 1-7 for details about placement of mounting holes. The XVG/eXVG can be mounted with any directional orientation, whether horizontal, vertical, or at an angle. However, PECC recommends the XVG/eXVG be mounted such that the Flow arrow on the body of the unit (see Figure 1-6) is pointing up or down. This orientation has the solenoid
operating along a vertical axis and will thus reduce wear on the XVG/eXVG. High strength bolts (0.3125in. diameter) are required to secure the controller enclosure to a user-provided mount bracket.
Note: Ensure adequate clearance is provided to the OUTLET and to the electronics cover to facilitate installation and maintenance.
Note: To maintain flow control accuracy, ten-(10) pipe diameters (15 inches) straight length minimum is recommended upstream and downstream.
The aluminum-body XVG weighs approximately 36 lbs. The aluminumbody eXVG weighs approximately 38 lbs. PECC recommends the use of lifting equipment to lift the valve.
Use special care when lifting by hand. Serious back injury may result without appropriate lifting equipment.
Figure 1-5. XVG/eXVG Dimensions with Harness as Electrical Interface (XVG shown)
Pipe Connections
The standard pipe connections for the XVG/eXVG are: XVG = SAE J518 -24 (1.5 inch), code 61 eXVG = SAE J518 -32 (2.0 inch), code 61
The valve bodies contain locking helical inserts. Contact Precision Engine Controls Corporation for other connection options.
Note: Use only SAE conforming mating connections. Use of non-conforming connections may change valve calibration.
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 the following bolts and torque values: XVG = 1/2 13 x 1-1/2, UNC-2A SAE Grade 5 or better. eXVG = 1/2 13 x 1-3/4, UNC-2A SAE Grade 5 or better
Do not over-torque fittings. Stripped threads or helical insert damage may result.
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Terminal Block Option The XVG/eXVG is available in configurations with internal terminal blocks as the electrical interface. The top cover of the XVG/eXVG must be removed to access the terminal blocks. See Figure 1-9 for a view of the terminal blocks. See Figure 1-11 for cover-removal and installation instructions.
Terminal Blocks
Any XVG/eXVG with the terminal blocks as the electrical interface features a threaded entry port (3/4in. NPT) to allow wiring between the electronics enclosure of the unit and the power supplies and controller. The XVG/eXVG is shipped with a plastic cap filling this entry port to prevent foreign matter from entering the electronics enclosure.
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Note: It is important that the cover and enclosure surfaces are free from scoring and that the cover bolts are tightened with the proper torque to maintain the explosion-proof rating. Prior to installing a conduit into the threaded port, wrap Teflon tape on the male threads of the conduit to ensure an adequate seal. Tape should cover the entire thread area, with no more than two layers of tape on the threads. The conduit should be tightened to a minimum of 45 ft-lbs. of torque, with at least 5 full threads on the conduit engaged,
Explosion-Proof Wiring Installation
An explosion-proof seal, such as a hazardous location fitting or conduit box with an approved seal, must be provided within 18 inches of the wire entry port to comply with Canadian Standards Association (CSA), Class I, Division 1, Group B, C and D requirements. This seal must also be provided at the electronics enclosure wire entry per European Union (EU) ATEX standards. The seal must be compliant and installed per local European Union requirements. See Figure 1-10 for the recommended type of explosion-proof connector for the XVG/eXVG.
Ground Connections
The case of the XVG/eXVG features an external lug that is attached to the housing with a screw and washers. This grounding lug is located on the output side of the unit, just below the top cover, and it is unlabeled. See Figure 1-11 for details and connection instructions. The grounding lug, screw, and washers are provided. The XVG/eXVG also features an internal grounding lug for those versions that use the internal terminal blocks as the electrical interface. See Figure 1-11 for details and connection instructions.
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14
Power Connections
The XVG/eXVG requires two power connections. To the Solenoid To the Electronics
Power Connection to Solenoid The solenoid of the XVG/eXVG operates on a 24VDC (nominal), userprovided input voltage. This voltage is supplied to the unit through either the integral wire harness or the terminal blocks, depending on the Electrical Interface configuration (see Section 2.2 for details).
FUNCTION
Solenoid Power Solenoid Return
WIRE COLOR
ORANGE RED
TERM. #
19 20
Power Connection to Electronics The electronics of the XVG/eXVG operate on a 24VDC (nominal), userprovided input voltage. This voltage is supplied to the unit through either the integral wire harness or the terminal blocks, depending on the Electrical Interface configuration (see Section 2.2 for details).
FUNCTION
Electronics Power Electronics Return
WIRE COLOR
VIOLET BLUE
TERM. #
21 22
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WARNING
The user must ensure proper 24 VDC electronics power levels, because the XVG/eXVG will NOT produce a fault signal if the 24 VDC electronics input power voltage is outside the specified range.
Table 1-3 below lists the power supply requirements for the XVG/eXVG.
PARAMETER
Voltage
ELECTRONICS Value 24 VDC 16 VDC 32 V (see Note) 2 VAC p-p, max 1 Amp 0.5 Amps 130 mA
Note: The maximum voltage specification includes both DC and AC (from ripple) components.
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Signal Connections
The XVG/eXVG transmits and receives signals through either the integral wiring harness or the terminal blocks, depending on the Electrical Interface configuration (see Section 2.2 for details). Signal Connections to Users Controller Signals are sent between the XVG/eXVG and the users controller through the integral 13-wire or 15-wire signal harness or through the internal terminal blocks. See Tables 1-4 and 1-5 for the wire lists for these harnesses, as well as the corresponding terminal numbers.
FUNCTION
AICH0 (Demand) AICH0 RTN (Demand RTN) AOCH0 (Feedback) AOCH0 RTN (Feedback RTN) FAULT ALARM FAULT RTN Serial/TX Out A Serial/RX In A Serial RETURN A
WIRE COLOR
BROWN GREEN YELLOW BLACK WHITE / ORANGE WHITE / BLACK / ORANGE WHITE / ORANGE / BLUE WHITE / ORANGE / YELLOW WHITE / ORANGE / GREEN
TERMINAL #
1 2 13 14 31 32 39 40 41
FUNCTION
AICH0 (Demand) AICH0 RTN (Demand RTN) AOCH0 (Feedback) AOCH0 RTN (Feedback RTN) AOCH1 AOCH1 RTN FAULT ALARM FAULT RTN Serial/TX Out A Serial/RX In A Serial RETURN A
WIRE COLOR
BROWN GREEN YELLOW BLACK WHITE GREY WHITE / ORANGE WHITE / BLACK / ORANGE WHITE / ORANGE / BLUE WHITE / ORANGE / YELLOW WHITE / ORANGE / GREEN
TERMINAL #
1 2 13 14 15 16 31 32 39 40 41
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Note: For proper operation of the controller, the common mode voltage between the control inputs and the power inputs shall be less than 200 VDC.
Analog Inputs
The base XVG/eXVG configuration includes one analog input channel, A/I CH0, which is dedicated as the Demand signal. Additional analog input channels may be available as options (contact PECC for details). The XVG/eXVG can be configured to accept the analog input signals in either current form or voltage form. The current range for an analog input is 4 to 20 mA, where 4mA corresponds to a command of 0% and 20 mA corresponds to a command of 100%. See Figure 1-14 for a typical analog input current connection. The XVG/eXVG features two voltage configurations for the analog input channels. The voltage range for analog inputs is 0 to 5 VDC, where 0 VDC corresponds to a command of 0% and 5VDC corresponds to a command of 100%. The other voltage range for analog inputs is 1 to 5VDC, where 1 VDC corresponds to a command of 0% and 5VDC corresponds to a command of 100%. See Figure 1-15 for a typical analog input voltage connection.
ANALOG IN
TRANSIENT VOLTAGE SUPPRESSOR
+ 16.7K
ANALOG IN RETURN
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Analog Outputs
The base XVG/eXVG configuration includes one analog output channel, AOCH0, which is dedicated as the Feedback signal. The XVG/eXVG version with pressure sensors (p/n 5002801-00x) provides an additional analog output, AOCH1, for feedback. See Section 2.2 for details about different versions of the XVG/eXVG. Each analog output signal can be independently configured for either current form or voltage form. The current range for the analog outputs is 4 to 20 mA, where 4mA corresponds to an output signal of 0% and 20 mA corresponds to an output signal of 100%. See Figure 1-16 for a typical analog output current connection. The XVG/eXVG features three voltage configurations for the analog output channels. The first voltage range for analog outputs is 0 to 5 VDC, where 0 VDC corresponds to an output signal of 0% and 5VDC corresponds to an output signal of 100%. The second voltage range for analog outputs is 1 to 5VDC, where 1 VDC corresponds to an output signal of 0% and 5VDC corresponds to an output signal of 100%. See Figure 1-16 for a typical analog output current connection. The third voltage range for analog outputs is 0 to -5 VDC, where 0 VDC corresponds to an output signal of 0% and -5VDC corresponds to an output signal of 100%. See Figure 1-17 for a typical analog output voltage connection.
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Discrete Inputs
The discrete input channel D/I CH0 is dedicated as the Run/Stop command signal. D/I CH0 is shown on the nameplate but it is only available as an option. Additional user-definable, discrete input channels may also be available as options (contact PECC for details). The discrete inputs are 24 VDC ON (High) and 0 VDC OFF (Low). See Figure 1-18 for a typical discrete input connection.
The base XVG/eXVG configuration includes one discrete output channel, D/O CH0, which is dedicated as the FAULT ALARM signal. Additional user-definable, discrete output channels may be available as options (contact PECC for details). The discrete outputs are solid-state switches, which are normally closed. The control system provides a current-limited voltage bias of 24 VDC. See Figure 1-19 for a typical discrete output connection.
DISCRETE OUT
24VDC
RS232 Serial Communications Interface Signal levels for the serial communications input and output are per RS232 standards. See Figure 1-20 for a typical RS232 interface connection. See Table 1-6 for computer COM port pin-outs for RS232.
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COMPUTER
RTN
RTN
Tx
Rx
Note: The pin designations shown in Table 1-6 are for the COM port on the computer. Make sure that the wiring to the COM port mating connector correctly matches Transmit from the XVG/eXVG to Receive on the computers COM port, and vice versa.
Note: The maximum distance for RS232 serial connections is 50 ft. This will typically only allow for local interface with a laptop PC.
RS485 Serial Communications Interface (Optional) Signal levels for the serial communications input and output are per RS485 standards. See Figure 1-21 for a typical RS485 interface connection. See Table 1-7 for computer COM port pin-outs for RS485.
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X
SERIAL A B
Note: The pin designations shown in Table 1-7 are for the COM port on the computer. Make sure that the wiring to the COM port mating connector correctly matches Serial A from the XVG/eXVG to Serial A on the computers COM port.
Note: The maximum distance for RS485 serial connections is 4000 ft at 57.6 kbps.
Recommended Wiring
The recommended wiring is an 18-conductor shielded cable containing twisted-pair wires with individual shields. Ensure that all shielded cables are twisted conductor pairs with either a foil or braided shield. PECC recommends Belden 9332 shielded twistedpair audio, broadcast and instrumentation cable. All signal lines should be shielded to prevent picking up stray signals. Connect shields as shown in Figure 1-22. Wire exposed beyond the shield should be as short as possible.
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The maximum resistance for the solenoid power loop should be one (1) ohm. The maximum resistance for the electronics power loop should be five (5) ohms. The maximum resistance for the signal wire loop should be ten (10) ohms. See Table 1-8 for recommended wire sizes.
Note: The XVG/eXVG terminal blocks will accept wire sizes from 18 AWG to 22 AWG. An external junction box must be used if larger diameter wire is required.
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CAUTION
This valve is 89/339/EEC EMC Directive compliant (CE mark) using watertight, flexible conduit (plastic over steel) and Belden 9332 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.
24
25
INTENTIONALLY BLANK
26
27
Optional pressure sensors at the input and output ports provide the ability to determine flow. The XVG/eXVG can also be configured to track the fuel Demand signal in proportion to measured mass flow. Another optional configuration limits fuel mass flow by scaling the fuel Demand signal according to pre-programmed maximum and minimum fuel limit levels. See Section 3: Operating Modes of XVG/eXVG for details.
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Part Numbers
The part number for the XVG/eXVG is made up of two parts: the base part number and the extension. For example, the part number 5002800-001 has a base part number of 5002800 and an extension of -001
Base Part Number The part number designates the specific version and corresponding bill of material used to manufacture the XVG/eXVG. See Table 2-1
Description This is the baseline model of the XVG/eXVG. The Demand signal is used to directly modulate the flow tube assembly position. Flow is metered between the flow tube and outlet orifice in proportion to flow tube position and resultant flow area. Includes only one analog output channel. This is mechanically equivalent to the baseline model with the addition of pressure sensors at the inlet port and outlet port. Includes two analog output channels. Table 2-1. Part Numbers for XVG/eXVG
5002801
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Extension Numbers The XVG/eXVG is available in two different models: the XVG and the eXVG. The XVG is the base model. The eXVG is the larger flow-capacity model. The physical differences between the XVG and eXVG are that the eXVG has: larger inlet and outlet plates to accept 2.0 inch flanges (rather than 1.5 inch flanges with the XVG) contoured inlet larger output port
Both the XVG and eXVG are available in Main valve and Pilot valve form. A Pilot-type XVG, for instance, is the same as the Main-type XVG, with the exception that a larger flow body is used. This reduces the flow area of the Pilot valve to approximately 60% of the flow area of the corresponding Main valve. The result is that a Pilot valve will have finer resolution but will only support lower flow levels than the corresponding Main valve. See Section 3.1 for additional details. The part number extension used to describe a valve indicates the model and the type of the valve. See Table 2-2.
Part # Extension -001 -002 -003 -004 -005 / -009 -006 / -010 -007 / -011 -008 / -012
Type Main, RS232 Pilot, RS232 Main, RS232 Pilot, RS232 Main, RS485 Pilot, RS485 Main, RS485 Pilot, RS485
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The PDN and its associated parameters and values must be defined and referenced in the procurement process of this product. Contact Precision Engine Controls Corporation for assistance in defining this number and its associated parameters and values for your application.
Operation Mode (MODE) The XVG/eXVG can operate in four different modes, as described in Table 2-3. The 5002800, the basic version of the XVG/eXVG, can only operate in Stroke mode. The 5002801 can operate in all 4 modes. See Sections 2.3 and 3.2 of this manual for additional information about operation modes of the XVG/eXVG.
# 0 1 2
Description Valve position (stroke) is a direct function of command value Valve position (stroke) is a direct function of command value. Measured flow is provided as an analog output signal, typically on AOCH1. Command signal specifies requested flow in PPH. Valve automatically adjusts metering of the flow tube assembly to achieve flow as defined by the command signal and scaled by the Max Flow parameter of the PDN. Command signal specifies requested flow in PPH based on a schedule of max/min flow values at a number of outlet pressure values. Valve automatically positions metering flow tube to achieve flow as defined by the command signal and interpolated from the flow schedule. Table 2-3. Operation Mode Configuration
Flow Limiting
Command Signal (CMD) The Command Signal parameter in the PDN describes the signal format and range of the fuel Demand signal used to control the XVG/eXVG. See Table 2-4 for details.
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# 0 1 2
Description 4 mA = 0% command 20 mA = 100% command 0 VDC = 0% command 5 VDC = 100% command 1 VDC = 0% command 5 VDC = 100% command
Analog Output Channels (AOCH0 & AOCH1) Analog output channels 0 and 1 (AOCH0 and AOCH1) are feedback signals. Two digits in the PDN describe each channel. The first digit represents the parameter represented by the feedback signal on that channel. See Table 2-5. The second digit represents the signal configuration, both format and range, for the feedback signal on that channel. See Table 2-6. The PDN shown in Figure 2-2, for example, has the two digits 12 for AOCH0. This means that the feedback signal on Channel 0 represents the valve position and the signal is in Volts, with a range of 1 to 5VDC.
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Description
0 1 2
The analog output channel is disabled. Output is scaled to report valve position. The output tracks Demand under normal operation in Stroke and Flow Measurement modes. Output is scaled to report measured flow: Minimum = 0 pounds per hour (PPH) Maximum = Max value specified in Maximum Flow Parameter Not applicable Output is scaled as a function of measured input pressure: Minimum = 0 psig Maximum = 500 psig Output is scaled as a function of measured output pressure: Minimum = 0 psig Maximum = 500 psig Output is scaled as a function of gas temp: Minimum = 0 C Maximum = 150 C
Table 2-5. Analog Output Parameter Channel Configuration
3 4
# 0 1 2 3
Description 4 mA = 0% 20 mA = 100% 0 VDC = 0% 5 VDC = 100% 1 VDC = 0% 5 VDC = 100% 0 VDC = 0% 5 VDC = 100%
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Gas Constants (R & k) The R parameter in the PDN represents the gas constant R for the gas being regulated by the XVG/eXVG. The k parameter in the PDN represents the specific heat ratio for the gas being regulated by the XVG/eXVG. These fuel properties vary for different gases. Flow measurement accuracy is based on accurate correlation of these properties with the media being measured. The Gas Constant numbers for R and k must correlate with the gas being regulated by the XVG/eXVG. The gas to be regulated must be defined in the procurement process for this product to ensure that the proper values for the constants are used. See Table 2-7.
Gas Constant R (ft-lbf / lbm-R) Gas Constant Air = 53.34 Natural Gas = 79.1 Propane = 35.04 k Specific Heat Ratio Cp/Cv Air = 1.4 Natural Gas = 1.273 Propane = 1.12
Description
Maximum Flow (MAX FLW) The MAX FLW parameter is used to scale the analog output channel. It is not the maximum flow capability of the XVG/eXVG. Maximum flow capability is a function of gas pressure and temperature conditions. Operating conditions must be carefully considered when choosing the maximum flow value for an application. See Table 2-8.
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Description Units are kPPH. This parameter scales the analog output when configured for measured flow. Table 2-8. Max Flow Configuration
Calibration Curve (CAL CURVE) Performance goals for flow and pressure for a given application are used to empirically determine the stroke and nominal flow area (CdA) needed at various points across the Demand signal range. The stroke values, and their corresponding flow area values, are plotted relative to Demand signal percentages (10%, 25%, 50%, 75%, and 100%, for instance) to define performance curves. Precision Engine Controls Corporation determines which calibration curve is necessary to achieve the customers desired performance profile across the Demand signal range. The Calibration Curve field in the PDN is used to identify the curve number that has been used to calibrate the unit. See Table 2-9.
Description Desired fuel flow and/or stroke vs. command characteristic for valve. Contact Precision Engine Controls Corporation for available flow characteristics. Table 2-9. Calibration Curve
Electrical Interface (ELECT) The Electrical Interface parameter specifies which one of the three electrical interface options has been used. See Table 2-10.
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# 0 1 2
Description Power and signal interfaces directly to the on-board terminal block. A thirteen-wire, explosion proof, pigtail harness is installed with the valve. A fifteen-wire, explosion proof, pigtail harness is installed with the valve. Table 2-10. Electrical Interface
Note. Hazardous Location Requirement: In order to comply with ATEX requirements, the user must install an explosion-proof seal within 18 inches of the valve enclosure exit when interfacing directly to the terminal block.
Flange Accessory (FLANGE) The Flange Accessory parameter specifies which one of the three flange accessory options has been used. See Table 2-11.
# 0 1 2
Description
MS33786-20 Flange, (4-Bolt) (XVG Only) SAE J518-24 TO ANSI #150 Flange (XVG Only) Table 2-11. Flange Interface
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Note. Contact Precision Engine Controls Corporation for details on flange conversions.
Stroke Mode
In stroke mode, the XVG/eXVG tracks the fuel Demand signal in proportion to the flow tube assembly position. As Demand increases, the solenoid exerts more force on the flow tube assembly, thus stroking open the valve until it reaches the appropriate position while further compressing the return spring. As Demand decreases, the solenoid exerts less force on the flow tube assembly, thus allowing the return spring to stroke closed the valve until it reaches the appropriate position. Positioning feedback from an LVDT is sent to a control loop to help control the flow tube assembly position. Flow is metered between the flow tube and orifice in proportion to flow tube position and the corresponding flow area (CdA). The flow area ranges from zero at 0% to maximum at 100%.
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represents zero flow. The maximum feedback signal represents maximum mass flow. This feedback signal is scaled by the MAX FLW parameter in the PDN.
Note. Flow Control Mode will not initiate until a positive 20 psid (inlet greater than outlet) is measured across the valve. As fuel Demand increases or decreases the controls energize the solenoid coil to the appropriate level and the flow tube strokes open or closed until the measured mass flow equals the commanded mass flow. As fuel Demand, pressure or temperature change, a control loop adjusts the flow tube position to establish the requested mass flow.
Housing Assembly
The housing assembly is a two-piece unit that consists of a machined valve body and an electronics enclosure. The enclosure attaches to the valve body with four attachment screws. A breather is incorporated into the housing assembly in order to vent any pressure build-up within the entire assembly. If any dynamic seal leaks occur, the resultant gas build-up will vent to ambient beginning at 1 or 2 psig. See Figure 2-5.
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Fuel flow is regulated by changing the position of the flow tube assembly.
Orifice Plate
The orifice plate is a machined assembly containing an orifice seal and flow divider. The orifice seal prevents flow leakage into the outlet.
Cover
The cover is a machined, o-ring sealed plate that allows access to the electronics terminal blocks.
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Control Electronics
The control electronics assembly contains two electronic assemblies. The control electronics are located within the housing assembly and are accessible via the cover. The control electronics assembly internally interfaces with the motor and LVDT along with temperature sensors and optional pressure sensors. External interfaces include analog, discrete and serial data. A digital signal processor (DSP) controls all valve functions. The control electronics interfaces with the engine control system and power supply. The assembly incorporates analog and discrete inputs and outputs, and a serial interface. It also provides signal conditioning for all internal analog and discrete I/O, as well as LVDT and sensor inputs. The digital signal processor (DSP) provides main control functions. All serial communication, PID control, health monitoring, A/D conversion and solenoid motor control is handled within the processor. An external watchdog IC is used to monitor the DSP. This IC also monitors the supply voltage to the DSP and will independently shut down the valve to close position in case of DSP catastrophic failure, low voltage, brownout condition, firmware problems and system hang conditions. The DSP converts analog inputs to digital counts for use in the control functions. The analog outputs are converted from digital counts and output to the user. A 10 kHz excitation signal is generated within the DSP to drive the LVDT. The LVDT output is signal conditioned and converted for digital position measurement. A control signal is sent to the solenoid drive circuit. Solenoid motor current is varied to control flow tube movement. Solenoid motor current feedback is provided to the DSP through isolation circuits. Signals from temperature sensors and optional pressure sensors are converted to digital counts and used in the control functions.
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Power
The XVG/eXVG operates on nominal 24 VDC input power. Two 24 VDC inputs are required. The electronics input provides power to the control electronics. The solenoid input provides power to the solenoid. Both power inputs are required for system functionality. The control electronics internal power supply isolates and conditions the 24 VDC input and converts it into 3.3 VDC, +15 VDC and 15 VDC. The internal power supply filters and protects against noise transients and reverse voltage. The internal power supply is isolated from the solenoid power.
Analog Inputs/Outputs
The XVG/eXVG receives analog inputs from an external, user-provided controller and also provides analog outputs. The XVG/eXVG includes a single analog input that is dedicated for the fuel Demand control signal. The base XVG/eXVG (p/n 5002800-xxx) provides a single analog output for feedback. The XVG/eXVG option with pressure sensors (p/n 5002801xxx) provides two analog outputs for feedback. Refer to Section 1: Installing the XVG/eXVG, for typical connections. Contact Precision
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Engine Controls Corporation regarding applications that require additional analog input and output. The analog input can be configured to operate with any of three different signal formats or ranges, as described in Table 2-4. The two analog output channels can be configured independently to operate with any of four different signal formats, ranges or polarities as described in Table 26. Refer to Section 1.2: General Specification Summary, for load values. Analog Input Channel 0 (AICH0) is configured for the fuel Demand signal. Analog Output Channel 0 (AOCH0) is typically configured for the valve position feedback signal. Analog Output Channel 1 (AOCH1) is typically configured for the flow measurement feedback signal. See Section 2.2: Versions of the XVG/eXVG (PDN) for a description of how the valve can be configured.
Discrete Inputs/Outputs
Discrete Input Channel 0 (DICH0) is not currently implemented. Discrete Output Channel 0 (DOCH0) is the Fault alarm which is configured as Trip to Open on a fault condition. These discrete interfaces are optically isolated. Refer to Section 1: Installing the XVG/eXVG, for a typical connection.
Serial Interface
The XVG/eXVG contains a single, optically isolated RS232 or RS485 (optional) serial communication interface. The serial interface communicates set-up parameters, performance conditions and fault diagnostics. Refer to Section 1: Installing the XVG/eXVG, for a typical connection.
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Figure 2-7. Typical Identification Plate for XVG, p/n 5002800-001 or -002
Figure 2-8. Typical Identification Plate for eXVG, p/n 5002800-003 or -004
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Figure 2-9. Typical Identification Plate for XVG, p/n 5002801-001 or -002
Figure 2-10. Typical Identification Plate for eXVG, p/n 5002801-003 or -004
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Demand Signal
The analog input signal (AICH0) is the only signal used to control the performance of the XVG/eXVG. It is also referred to as the fuel Demand signal. The XVG/eXVG can be configured to accept one of three different command signal formats, as described in Table 3-1 below. The command signal format used for a unit is described in its PDN, as described in Section 2.2 of this manual.
Description 4 mA = 0% command 20 mA = 100% command 0 VDC = 0% command 5 VDC = 100% command 1 VDC = 0% command 5 VDC = 100% command
Command signal levels are often referred to as percentages of their ranges rather than as absolute values. Table 3-2 lists percentage values for the three command signal formats supported by the XVG/eXVG.
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% of Range 0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100%
0 to 5 V 0V 0.5 V 1.0 V 1.5 V 2.0 V 2.5 V 3.0 V 3.5 V 4.0 V 4.5 V 5.0 V
1 to 5 V 1.0 V 1.4 V 1.8 V 2.2 V 2.6 V 3.0 V 3.4 V 3.8 V 4.2 V 4.6 V 5.0 V
What the command signal is actually controlling depends on the operating mode for which the XVG/eXVG is configured.
Feedback Signal
The analog output signal (AOCH0) is used to monitor the performance of the XVG/eXVG. It is also referred to as the Feedback signal. Upon installation, it is important to ensure 24 VDC is applied to the XVG/eXVG before gas pressure is supplied otherwise factory calibration could be affected. This is because the zero position of the Feedback signal is calibrated each time power is supplied or a software reset is performed.
Note. Ensure 24 VDC is applied before gas pressure to prevent changing the factory calibration.
Flow Area
The only moving part in the XVG/eXVG is the flow tube assembly. The position and movement of the flow tube assembly are referred to as the stroke of the valve. The XVG/eXVG has a maximum stroke of 0.250in. The position of the flow tube assembly determines the actual amount of area through which the fuel can flow. When the position is at 0.0in., the flow area is zero because the valve is closed and no gas can flow. When
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the position is at its maximum value of 0.250in., the valve is fully open and the flow area is at its maximum. The maximum flow area for the XVG/eXVG is an indication of its fuel-flow capacity. Table 3-3 lists the maximum flow area for each version of the XVG/eXVG.
Maximum Flow Area (in2) CdA (sonic) 0.49 0.32 0.60 0.32
Version of Valve XVG Main XVG Pilot eXVG Main eXVG Pilot
Calibration Curves
Performance goals for flow and pressure for a given application are used to empirically determine the stroke and nominal flow area (CdA) needed at various points across the Demand signal range. The stroke values, and their corresponding flow area values, are plotted relative to Demand signal percentages (10%, 25%, 50%, 75%, and 100%, for instance) to define performance curves. While the XVG/eXVG has a full-range stroke capability of 0 to 0.250 inches, some applications may only require that a portion of this range, such as 0 to 0.130 inches, be used. Other parameters that are used in defining calibration curves may include minimum and maximum values for inlet pressure, outlet pressure, flow rate, and feedback percentage. Precision Engine Controls Corporation determines the proper calibration curve, and other parameters, necessary to achieve the customers desired performance profile across the Demand signal range for a particular application. A calibration curve is used for every XVG/eXVG and is incorporated into the PDN (see Section 2.2 for details).
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Stroke Mode
In Stroke Mode, the Demand signal directly controls the position of the flow tube assembly. The LVDT provides precise feedback about the flow tube position to the electronics of the XVG/eXVG, thus allowing the stroke to accurately track the Demand signal.
Demand Signal
A Demand signal of 0% will move the flow tube assembly to the minimum position, which results in a closed valve. A Demand signal of 100% will move the flow tube assembly to the maximum position of its range, as determined by the calibration curve for the unit. The calibration curve determines the flow tube position for Demand signal levels between 0% and 100%. See Figure 3-1 for a representation of Stroke vs. Demand signal performance.
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Demand Signal
A Demand signal of 0% will move the flow tube assembly to the minimum position, which results in a closed valve. A Demand signal of 100% will move the flow tube assembly to the maximum position of its range, as determined by the calibration curve for the unit. The calibration curve determines the flow tube position for Demand signal levels between 0% and 100%. See Figure 3-1 for a representation of Stroke vs. Demand signal performance.
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Demand Signal
A Demand signal of 0% will set the flow rate at 0 kPPH, resulting in the valve closing. A Demand signal of 100% will set the flow rate to the units maximum flow rate, depending on pressure and temperature conditions. The calibration curve used for a XVG/eXVG unit in Flow Control mode is a linear stroke for Demand signal levels between 0% and 100%. See Figure 3-2 for a representation of Flow Rate vs. Demand signal performance.
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When the Demand signal changes, the XVG/eXVG uses the outlet pressure to determine the flow-rate that corresponds to the new Demand signal under the existing conditions. The XVG/eXVG compares the commanded flow rate to the measured flow rate. The difference between the commanded and measured flow rates, known as the flow error, is used to determine the position set point. The XVG/eXVG initiates a stroke to move the flow tube assembly to the new position, which will in turn have a flow rate closer to the commanded flow rate. If any flow error is detected after the move, the XVG/eXVG will change the position set point again, causing another position adjustment. The XVG/eXVG will continue adjusting the flow tube assembly position until the measured flow rate matches the commanded flow.
Demand Signal
At a given outlet pressure, a Demand signal of 0% will set the flow rate to the minimum flow rate defined for that outlet pressure based on the calibration curve information. At a given outlet pressure, a Demand signal of 100% will set the flow rate to the maximum flow rate defined for that outlet pressure based on the flow-limiting curve information. Flow rates for Demand signal levels between 0% and 100% are linearly interpolated between the minimum and maximum defined flow rates for that outlet pressure. Maximum flow rates for outlet pressures that have not been explicitly defined are linearly interpolated between maximum flow rates for the closest outlet pressures that have been defined. Minimum flow rates for outlet pressures that have not been explicitly defined are linearly interpolated between minimum flow rates for the closest outlet pressures that have been defined. The pre-defined maximum and minimum flow rate vs. outlet pressure information is part of the calibration information for a XVG/eXVG unit in Flow Limiting mode. PECC determines the proper calibration curve to use for each application based upon the customers desired flow rate characteristics. Contact PECC for details. See Figure 3-3 for a representation of Flow Rate vs. Outlet Pressure curves that are used in Flow Limiting mode.
3.3 Feedback
The XVG/eXVG offers either one or two analog output channels, depending on the configuration. Units with the base part number 5002800 have one analog output channel, AOCH0. Units with the base part number 5002801 have two analog output channels, AOCH0 and AOCH1. Each of the analog output channels on the XVG/eXVG can be
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configured independently to use one of four different feedback signal formats, as described in Table 3-4. The feedback signal format used for each analog output of a unit is described in its PDN, as described in Section 2.2 of this manual.
Description 4 mA = 0% 20 mA = 100% 0 VDC = 0% 5 VDC = 100% 1 VDC = 0% 5 VDC = 100% 0 VDC = 0% 5 VDC = 100%
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The analog outputs can also be configured to provide feedback for five different parameters. See Table 3-5 for a description of these parameters. Units with the base part number 5002800 do not have pressure sensors, so they can only provide feedback for Stroke or Gas Temperature. Units with the base part number 5002801 have pressure sensors, so they can provide feedback for any of the five parameters shown in Table 3-5. Analog output AOCH0 is typically configured for Stroke feedback. Analog output AOCH1 is typically configured for Flow Measurement feedback. (AOCH1 is disabled on units with the base part number 5002800.) The analog outputs can be configured for any of the five parameters shown in Table 3-5, but deviations from the typical analog output configuration must be indicated in the PDN when the unit is being ordered.
Analog Output Parameter
DESCRIPTION
Stroke
Output is scaled to report the flow tube assembly position. Output tracks Demand signal under normal operation in Stroke Mode and Flow Measurement Mode. Output is scaled to report measured flow: Minimum = 0 PPH Maximum = Max. value specified in Maximum Flow Parameter in PDN Output is scaled as a function of measured input pressure: Minimum = 0 psig Maximum = 500 psig Output is scaled as a function of measured output pressure: Minimum = 0 psig Maximum = 500 psig Output is scaled as a function of gas temp output pressure: Minimum = 0 C Maximum = 150 C
Table 3-5. Feedback Parameter Configuration
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unit and output a discrete FAULT alarm to the users controller. The XVG/eXVG firmware also captures the fault data in an EEPROM.
FAULT Alarm
The FAULT alarm is a non-latching, solid-state contact from the XVG/eXVG. Upon power-up, the FAULT circuit closes and stays CLOSED in the normal operating condition. When the XVG/eXVG detects a system fault, it opens the FAULT circuit. If a critical system fault is detected the XVG/eXVG will enter a shutdown state immediately. Non-critical faults will trigger the FAULT alarm as a warning, but they will not cause a shutdown. See Table 5-4 of this manual for a list of faults, possible causes, and the action taken when the fault is detected (shutdown or warning). A fault file can be uploaded from the XVG/eXVG using PECCs proprietary XView software via the RS232 or RS485 (optional) interface. See Section 5.2. The fault file will provide fault information and possible causes. Contact Precision Engine Controls Corporation to request this software.
Shutdown State
The Shutdown State is a safety condition that will prevent uncontrolled operation of the valve. In a shutdown state the Pulse Width Modulator (PWM) output from the DSP is removed so the valve will close and not respond to command. The XVG/eXVG will not respond to the Demand signal until the faulting condition is removed. If the faulting condition is not known, try cycling power OFF then ON. If the problem that caused the shutdown is no longer present, the XVG/eXVG will return to a normal operating state. If the problem is still present, the XVG/eXVG will resume a shutdown state. It is important to retrieve the fault file from the XVG/eXVG in either situation to determine the nature of the fault and possible causes. See Section 5.2 of this manual for details about how to upload the fault file from the XVG/eXVG.
Note: The only way to exit the Shutdown State is to first remove the condition that caused it. Once the faulting condition is removed, the XVG/eXVG will function normally.
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Note. Keep a maintenance log for the XVG/eXVG fuel-metering valve. A service history makes it easier to establish a maintenance schedule.
Visual Inspection
Perform the following visual examination every week. Inspect the valve exterior for loose or broken parts. Pay particular attention to wires, shields and connectors. Thoroughly inspect wires and cables for wear, fraying, or damage. Repair any damaged areas you may find. Check fuel lines and fittings for leaks or damage.
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External Cleaning
Clean the valve exterior every 60 to 90 days, or more often, as the environment dictates. This cleaning aids the visual inspection and prevents unwanted dirt build-up. Be sure to depressurize the fuel system before cleaning the valve. The XVG/eXVG can be externally cleaned with a jet of water. The XVG/eXVG enclosure is environmentally rated to NEMA 4 and European IP56. As such, the XVG/eXVG can withstand a strong water jet directed at its enclosure with no harmful effects. The test conditions necessary to secure the environmental rating involved a jet nozzle with an inside diameter of 12.5-mm splashing a volume of 100 liters per minute from a distance of 2.5-3 meters from all sides of the enclosure for duration of 3 minutes. Precision Engine Controls Corporation recommends that the flow rate of the water jet used in the cleaning, as well as the duration of the cleaning, not exceed the flow rate and duration used in the environmental rating test.
WARNING - Explosion Hazard Serious injury may result if cleaning is performed while valve is pressurized. Depressurize fuel system prior to valve cleaning. The following procedure is an alternate method of cleaning the XVG/eXVG. Depressurize the fuel system prior to cleaning the valve. Remove loose dirt with low pressure, clean dry air. Carefully wipe exterior surfaces with clean cloth and either mild soap and water or ethyl alcohol.
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Required Items
Corrective maintenance actions require the following items: Precision Engine Controls Corporation special tool; P/N 5003760-001 for the XVG or P/N 5003948-001 for the eXVG Orifice seal replacement kit; P/N 5003261-001 or -002 (XVG only) O-ring; P/N M83248/1-034 (XVG), P/N M83248/2-037 (eXVG), O-ring lubricant, such as Parker O-Lube Solvents for cleaning (see below for recommended solvents)
Recommended Solvents Chlorinated solvents such as ethylene dichloride, Freon or similar chemicals are excellent for dissolving petroleum-based contaminants such as tar, paraffin and other hydrocarbons. Denatured alcohol may also be used, but it will not be as effective as the chlorinated solvents. Certain ketone solvents, such as Acetone and MEK (Methyl-Ethyl Ketone), can damage the Viton o-ring seals contained within the valve. If a ketone is used as a cleaning agent, make sure to limit the exposure time to no more than five minutes. Use shop air to ensure all residual solvent has evaporated.
Orifice Cleaning
WARNING - Explosion Hazards
This procedure involves handling explosive mixtures. Ensure venting is adequate and fuel is diluted in order to prevent explosion.
Serious injury may result if cleaning is performed while valve is pressurized. Depressurize fuel system prior to valve cleaning.
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Use Latex or other appropriate hand protection when cleaning or disassembling valve.
The XVG/eXVG can be cleaned while it is on the engine, as long as the valve OUTLET is accessible.
Procedure 4.2.1
To clean the orifice, follow these steps: a) Depressurize the fuel system. b) Secure the fuel system. c) Remove the engine igniter circuit breaker. d) Remove the valve OUTLET fuel line. e) Remove 24VDC f) Remove the orifice plate using Precision Engine Controls Corporation special tool; P/N 5002994-001 for the XVG or P/N 5003948-001 for the eXVG, as shown in Figure 4-1 or Figure 4-2, respectively.
Note. Remove the orifice slowly to ensure the orifice seal and orings are not damaged. Contact Precision Engine Controls Corporation for special tool P/N 5002994-001 for the XVG or P/N 5003948-001 for the eXVG to assist with this step.
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h) Clean away dirt and contaminants using the solvents recommended at the beginning of Section 4.2. Ensure that the orifice plate is clean and dry. See Figure 4-3 for a photo of the XVG orifice plate. See Figure 4-4 for a photo of the eXVG orifice plate i) Inspect the orifice seal and o-ring for nicks, scrapes and damage. If the orifice seal is damaged, contact Precision Engine Controls Corporation for the orifice seal replacement kit; P/N 5003261-001 or -002. If the o-ring seal only is damaged, contact Precision Engine Controls Corporation for o-ring; P/N M83248/1-034 (XVG).or P/N M83248/2-037 (eXVG). Install the o-ring seal. Lubricate, as necessary, using an o-ring lubricant, such as Parker O-Lube.
j)
k) Install the orifice plate slowly using Precision Engine Controls Corporation special tool; P/N 5002994-001 for the XVG or P/N 5003948-001 for the eXVG. l) Torque the orifice plate to 8 to 10 ft-lbs. m) Reconnect the OUTLET fuel line. Torque the flange bolts to 550700 in-lb.
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WARNING
Do NOT score the outer diameter of the flow tube. This could cause an external fuel leak.
Procedure 4.2.2
a) Perform steps a) through h) of Procedure 4.2.1. b) Using a soft bristle brush and solvents recommended at the beginning of Section 4.2, gently clean the inside of the flow tube. Clean any visible contaminants on the visible outer diameter. c) Dry the tube inside of the flow tube using a soft towel or shop air. d) Repeat steps 4.2.1 h) through m).
4.3 Calibration
Re-calibration in the field is not generally recommended or feasible because flow calibration procedures require special equipment not normally available in the field. Return the XVG/eXVG to the factory for recalibration if adjustments are necessary. Contact Precision Engine Controls Corporation for Return Material Authorization (RMA) before shipping the valve back to the factory.
4.4 Refurbishment
Contact PECC for details about refurbishment options for the XVG/eXVG.
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WARNING
Operating the valve while it is in a malfunctioning condition may cause serious injury or equipment damage.
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Table 5-3 lists some common failures that can be expected after equipment has been installed. These failures are usually due to power supply problems or failures within the valve. Use the XView Communications software to determine if there are any failures inside the valve. Refer to Section 5.3 for information regarding these faults.
Function Demand Input 0 Analog Output 0 Analog Output 1 Solenoid Power Electronics Power Discrete Input 0 (option) Fault Alarm Output 0
Wire Color Brown Green Yellow Black White Grey Orange Red Violet Blue WHT/VIO WHT/BLK/VIO WHT/ORN WHT/BLK/ORN
Terminal # 1 2 13 14 15 16 19 20 21 22 23 24 31 32
Impedance Value 16.3 to 17.0 K * High Impedance ** > 200 K High Impedance ** > 200 K High Impedance > 1.0 M High Impedance > 200 K High Impedance > 200 K High Impedance *** > 200 K
* Reference Figures 1.14 and 1.15 ** Reference Figures 1.16 and 1.17 *** Reference Figure 1.19 Table 5-1. XVG/eXVG Expected Circuit Impedance
Note. All impedance measurements shall be performed with no power applied to the XVG/eXVG and the wire pair under measurement is disconnected from the system.
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Pressure Faults
A pressure fault indicates a pressure sensor failure or an external system problem. Check the fault and investigate the source of the over- or underpressure condition. In the case of a sensor malfunction, return the valve to Precision Engine Controls Corporation for repair or replacement. Contact Precision Engine Controls Corporation for Return Material Authorization (RMA) before shipping the valve back to the factory.
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Probable Causes Electrical wires not connected No or low 24 VDC power Incorrect Output Set-Up
Corrective Action Ensure wires connected to terminal 13, 14, 21, 22 Ensure 24 VDC across terminal 21 and 22 Ensure proper A/O Channel set-up Ensure wires connected to terminal 19 and 20 Ensure solenoid power and return connected. Ensure 24 VDC across terminal 19 and 20 Ensure valve is in desired operating mode Verify that Demand signal format being used matches setting shown in the PDN Verify that the inlet pressure is at least 20 psid greater than the outlet pressure Ensure wires connected to terminal 1, 2 and that Demand > minimum value Ensure stable fuel Demand at the valve Ensure 24 VDC across terminal 19 and 20 Ensure shields connected per Fig. 1-20 Remove orifice and clean debris Ensure shields connected per Fig. 1-20 Ensure pipe flange is flush mounted Remove orifice and clean debris Ensure flow direction matches FLOW arrow Ensure connected to terminal 39, 40, 41 Ensure 24 VDC across terminal 21 and 22 Check laptop/PC com port
Solenoid wires not connected Solenoid wires reversed No or low 24 VDC power level Incorrect Set-Up
No fuel Demand Valve does not hold consistent positionoscillates or dithers Valve closed feedback >4.1 mA Varying fuel Demand signal No or low 24 VDC power Improper grounding Flow tube seal fouled Improper grounding Non-conforming SAE flange Valve leaks when closed Flow tube seal fouled Valve installed backwards RS232 or RS485 Interface Inoperative Incorrect wiring No or low 24 VDC power COM1 not connected
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Corrective Action Ensure 24 VDC across terminal 21 and 22 Upload Fault File- check for faults. Take action on any faults found. Ensure 24 VDC across terminal 19 and 20 Ensure wires connected to terminal 1, 2 and Demand > minimum Upload Fault File- check for faults. Take action on any faults found. Remove orifice and clean debris Remove and replace seal
WARNING
The user must ensure proper 24 VDC electronics power levels, because the XVG/eXVG will NOT produce a fault signal if the 24 VDC electronics input power does not meet specifications. The 24 VDC power is converted to 15V and 3.3V within the XVG/eXVG for use with the internal components. A fault signal will only be triggered if the 15V or 3.3V power levels are out of their respective ranges.
Critical Faults
The following are considered critical system faults because they may be indications of major problems with the valve. 3.3 V 15V Tracking error LVDT sensor Pressure sensor (inlet or outlet) Setup checksum Temperature sensor (gas or electronics) Watchdog
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Contact Precision Engine Controls Corporation for assistance with troubleshooting if any of these faults are encountered. The valve may need to be returned to Precision Engine Controls Corporation for repair or replacement. Contact Precision Engine Controls Corporation for Return Material Authorization (RMA) before shipping the valve back to the factory.
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Fault Description 3.3V low 3.3 V high Tracking Gas Temp. low Gas Temp. high Gas Temp. shutdown Inlet Pressure low Inlet Pressure high Outlet Pressure low Outlet Pressure high LVDT A+B low LVDT A+B high LVDT AB low LVDT AB high LVDT pos limit Setup checksum Flow setup Solenoid Current Inlet overpressure Outlet overpressure +15V low +15V high 15V low 15V high Elec. Ambient Temp. low Elec. Ambient Temp. high Watchdog
Fault # 1 2 10 21 22 23 41 42 51 52 61 62 63 64 65 70 80 90 101 102 110 111 120 121 130 131 150
Limit 2.97 3.63 Pos. 0.025in. over Demand 20 C 130 C 140 C 5.0 psia 520 psia 5.0 psia 520 psia 0.01 0.04 0.04 0.04 0.2625in. n/a n/a Factory-configurable 515 psia (eXVG) 450 psia (XVG) 515 psia (eXVG) 450 psia (XVG) 13.5V 16.5V 16.5V 13.5V 50 C 125 C n/a
Set Time 40 ms 40 ms 1 sec 1 sec 1 sec 10 sec 100 ms 100 ms 100 ms 100 ms 40 ms 40 ms 40 ms 40 ms 40 ms 0 ms 0 ms n/a 100 ms 100 ms 40 ms 40 ms 40 ms 40 ms 1 sec 1 sec 5 ms
Fault Action Shutdown Shutdown Shutdown Warning Warning Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Warning Warning Warning Warning Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown Shutdown
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Decommissioning
For removal follow proper lockout /tagout procedures and verify no live electrical circuits: Disconnect the 4 power wires, whether part of the integral wire harness or connected to terminals, from the system power supplies or batteries. Disconnect the 9 or 11 signal wires, whether part of the integral wire harness or connected to terminals, from the system circuitry.
Disposal
Follow local environmental codes in regards to disposal of electronic components, specifically all electrolytic capacitors. Decommissioned units may also be returned to Precision Engine Controls Corporation for disposal in most cases. Contact the factory for details and return authorization before shipping decommissioned units.
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