Mecanica

Contents–1
Contents
Document Introduction . . . . . . . . . . . . . . . . . . 1-1
Document Content . . . . . . . . . . . . . . . . . . . . . . . . . .1-1
Conventions Used in This Document . . . . . . . . . . . . . . . . .1-2
Product Description . . . . . . . . . . . . . . . . . . . . 2-1

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-2
Electronic Control System . . . . . . . . . . . . . . . . . . . . . .2-4
Nonisolated Output Feedback . . . . . . . . . . . . . . . . . . . .2-5
Controller Status Relays . . . . . . . . . . . . . . . . . . . . . . .2-5
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-5
Product Information . . . . . . . . . . . . . . . . . . . . 3-1

Receiving . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3-1
Returned Material Authorization . . . . . . . . . . . . . . . . . . .3-1
Nameplate Data and Product Identification . . . . . . . . . . . . . .3-2
Model and Part Numbers . . . . . . . . . . . . . . . . . . . . . . .3-2
Fuel Valve Model Code . . . . . . . . . . . . . . . . . . . . . .3-3
Actuator Controller Model Code. . . . . . . . . . . . . . . . . .3-3
Flange and Accessories Kit . . . . . . . . . . . . . . . . . . . . . .3-5
Installation . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-1
Power and Input Requirements . . . . . . . . . . . . . . . . . . . .4-2
Fuel Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-3
Fuel Valve Vent Connection. . . . . . . . . . . . . . . . . . . .4-4
Cable Entry Gland. . . . . . . . . . . . . . . . . . . . . . . . .4-4
Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4-4
Model 8412 Actuator Controller. . . . . . . . . . . . . . . . . . . .4-5
UM8402 (4.0) – Rotary Fuel Valve and Controller for Gas Turbine Applications
Contents–2
Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . 4-6

Control and Feedback Cables . . . . . . . . . . . . . . . . . . 4-6
Motor Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Position Cable . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7
Power Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Configuration and Operation . . . . . . . . . . . . . . . 5-1

Actuator Mechanical Stop Setup . . . . . . . . . . . . . . . . . . 5-1
Position Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Operating Modes . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5
DIP Switch (SW1) Settings . . . . . . . . . . . . . . . . . . . . . 5-5
User Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Push Buttons . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
LCD Display . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6
Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Controller Software Version . . . . . . . . . . . . . . . . . . . 5-7
Manual Position . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Auto Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Fully Closed Position. . . . . . . . . . . . . . . . . . . . . 5-7
Fully Open Position . . . . . . . . . . . . . . . . . . . . . 5-9
Manual Setup (Alternative) . . . . . . . . . . . . . . . . . . . 5-10
Fully Closed Position. . . . . . . . . . . . . . . . . . . . . 5-10
Fully Open Position . . . . . . . . . . . . . . . . . . . . . 5-10
Control Action . . . . . . . . . . . . . . . . . . . . . . . . . . 5-10
Hysteresis . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Set Point Fail . . . . . . . . . . . . . . . . . . . . . . . . . . 5-11
Automatic Operation . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Power-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-12
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . 5-12
DC Power Failure . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Set Point Failure . . . . . . . . . . . . . . . . . . . . . . . . . 5-13
Valve Position (Encoder) Failure . . . . . . . . . . . . . . . . 5-13
EEPROM Corruption . . . . . . . . . . . . . . . . . . . . . . 5-14
Controller Status Relays. . . . . . . . . . . . . . . . . . . . . 5-14
January 27, 1998

Contents–3
Specifications . . . . . . . . . . . . . . . . . . . . . . . A-1
Installation Dimensions . . . . . . . . . . . . . . . . . . B-1
Wiring and Electronic Details. . . . . . . . . . . . . . . C-1
Component Identification . . . . . . . . . . . . . . . . . D-1
Mounting Details. . . . . . . . . . . . . . . . . . . . . . E-1
Spares . . . . . . . . . . . . . . . . . . . . . . . . . . . F-1
Product Return Form . . . . . . . . . . . . . . . . . . . G-1
Contents–4
Figures
Figure 2-1 Valve Flow Characteristic, Model 4280 . . . . . . . . . 2-2
Figure 2-2 1”, 2”, and 3” Rotary Fuel Valves and Actuator . . . . . 2-3
Figure 3-1 Rotary Fuel Valve Nameplate . . . . . . . . . . . . . . 3-2
Figure 4-1 Control Box Mounting . . . . . . . . . . . . . . . . . . 4-5

Figure 4-2 System Cabling Requirements . . . . . . . . . . . . . . 4-6
Figure 5-1 Precision Dowel Pin and Machined Slot . . . . . . . . . 5-1

Figure 5-2 Typical Flow Characteristic and Corresponding
Valve Trim Orifice Positions . . . . . . . . . . . . . . . 5-2
Figure 5-3 Valve Position Indicator Graduations. . . . . . . . . . . 5-4
Figure 5-4 Controller Setup Sequence. . . . . . . . . . . . . . . . 5-8
Figure 5-5 System Layout for Control of Fuel Valve . . . . . . . . . 5-12
Figure B-1 Installation Dimensions – Actuator Controller . . . . . . B-1

Figure B-2 Installation Dimensions – 1” Rotary Valve/Actuator . . . B-2
Figure B-5 Dimensions – Class 600 Weld Neck Flange for
2” Valve . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Figure B-6 Dimensions – ANSI Class 600 API 601 (Std) Spiral
Wound Gasket . . . . . . . . . . . . . . . . . . . . . . B-6
Figure C-1 Printed Circuit Board . . . . . . . . . . . . . . . . . . . C-1

Figure C-2 Wiring Details – Actuator Controller . . . . . . . . . . . C-2
Figure C-3 Power Supply/Interconnect Assembly (66281X1) . . . . C-3
Figure D-1 Component ID – Actuator Controller (8412) . . . . . . . D-1

Figure D-2 Component ID – Actuator Controller (8412) . . . . . . . D-2
Figure D-3 Component ID – Actuator . . . . . . . . . . . . . . . . D-4
Figure D-4 Component ID – Actuator/Valve Assembly
(2” Valve Shown) . . . . . . . . . . . . . . . . . . . . D-6
January 27, 1998

Contents–5
Figure D-5 Component ID – 1” Valve Subassembly . . . . . . . . . D-8

Figure D-6 Component ID – 2” Valve Subassembly . . . . . . . . .D-10
Figure D-7 Component ID – 3” Valve Subassembly . . . . . . . . .D-12
Figure E-1 1/2'' U-bolts for Mounting 2” and 3” Fuel Valves,

Model 4280 . . . . . . . . . . . . . . . . . . . . . . . E-1
Figure E-2 Hole Patterns for Mounting 2” and 3” Fuel Valves with
1/2'' U-bolts . . . . . . . . . . . . . . . . . . . . . . . E-2
Figure E-3 Hole Pattern for Mounting 1” Fuel Valve . . . . . . . . . E-2
Figure E-4 Mounting Details for 2” and 3” Fuel Valves
(2” Shown) . . . . . . . . . . . . . . . . . . . . . . . . E-3
Figure E-5 Mounting Details for 1” Fuel Valve . . . . . . . . . . . . E-4
Contents–6
Tables
Table 2-1 Flow Coefficients (Cv) for 1”, 2”, & 3” Valves. . . . . . . 2-1
Table 2-2 Flow Coefficient (Cv) Data . . . . . . . . . . . . . . . . 2-1
Table 3-1 Model Numbers . . . . . . . . . . . . . . . . . . . . . 3-2

Table 3-2 Ordering Information . . . . . . . . . . . . . . . . . . . 3-4
Table 3-3 Spare Fuse and Connector Kit (60-200610-SPR) . . . . 3-4
Table 3-4 RJR Flange and Accessories Kit for 2” Valve
(20190X003) . . . . . . . . . . . . . . . . . . . . . . . 3-5
Table 4-1 Flange Bolt Torque Values . . . . . . . . . . . . . . . . 4-4

Table 4-2 Motor Cable Length vs. AWG . . . . . . . . . . . . . . 4-7
Table 5-1 Valve Position for each Graduation . . . . . . . . . . . 5-4

Table 5-2 DIP Switch Settings for SW1 . . . . . . . . . . . . . . . 5-5
Table 5-3 LED Indications. . . . . . . . . . . . . . . . . . . . . . 5-6
Table A-1 Actuator Specifications . . . . . . . . . . . . . . . . . A-1
Table D-1 Component ID – Actuator Controller (8412) . . . . . . . D-3

Table D-2 Component ID – Actuator . . . . . . . . . . . . . . . . D-5
Table D-3 Component ID – Actuator/ Valve Assembly . . . . . . . D-7
Table D-4 Component ID – 1” Valve Subassembly . . . . . . . . . D-9
Table D-5 Flow Coefficient (Cv) Codes – 1” Valve . . . . . . . . . D-9
Table D-6 Component ID – 2” Valve Subassembly . . . . . . . . .D-11
Table D-7 Flow Coefficient (Cv) Codes – 2” Valve . . . . . . . . .D-11
Table D-8 Component ID – 3” Valve Subassembly . . . . . . . . .D-13
Table D-9 Flow Coefficient (Cv) Codes – 3” Valve . . . . . . . . .D-13
Table F-1 MTBF for Rotary Fuel Valve System . . . . . . . . . . F-1

Table F-2 Rotary Valve Parts . . . . . . . . . . . . . . . . . . . . F-1
Table F-3 Actuator Parts . . . . . . . . . . . . . . . . . . . . . . F-2
Table F-4 Actuator Controller Parts . . . . . . . . . . . . . . . . F-2
January 27, 1998

Document Introduction 1-1
Chapter 1: Document Introduction
This document is intended to provide all the information

necessary to configure and use the 1-inch, 2-inch, and 3-inch
Rotary Fuel Valves and the associated Actuator Controller
and flange kits.
Document The contents of this document are described below, with

additional detail shown in the table of contents.
Content
Chapter 1 — Introduces this manual and provides an outline
of the contents.
Chapter 2 — Describes the Rotary Fuel Valve system.
Chapter 3 — Provides general information on the Rotary
Fuel Valve system, including nameplate data, product
identification information, and receiving/inspection/storage
information.
Chapter 4 — Provides information on installing the Rotary
Fuel Valve system.
Chapter 5 — Provides information on configuring and
operating the Rotary Fuel Valve system.
Appendix A — Contains the specifications for the Rotary
Fuel Valve system.
Appendix B — Contains installation dimension drawings for
the actuator controller and each valve size.
Appendix C — Contains wiring and PCB diagrams for the
Rotary Fuel Valve system.
Appendix D — Contains component identification drawings
for the actuator controller and each valve size.
Appendix E — Provides mounting details for each valve size.
Appendix F — Contains spares information and
recommendations for the Rotary Fuel Valve system.
Appendix G — Contains a Product Return Form for the
An index and reader’s evaluation form are also included.
1-2 Document Introduction
Conventions The following conventions are used throughout this

document:
Used in This
Acronyms — All acronyms are defined at their first
Document ■
occurrence in the document and may be defined at other

places in the text.
■ Notes, Cautions, and Warnings — The following
conventions are shown in the format in which they appear
throughout the manual:
Note: Notes contain important information which needs to be

emphasized.
Caution: Cautions contain instructions which, if not followed, could

lead to irreversible damage to equipment.
Warning! Warnings contain instructions which, if not followed,

could lead to personal injury.
■ Revision Control — The document revision level follows

the document number (in parenthesis) in the footer of
odd-numbered pages. The document revision date is
found in the footer of even-numbered pages.
January 27, 1998

Product Description 2-1
Chapter 2: Product Description
The Rotary Fuel Valve system precisely controls the flow of

fuel to the combustion chamber of a gas turbine. A single
valve may be used to control ignition flow, start-up, and idle
flows, and may also be used for limiting control. This allows
for considerable simplification when retrofitting existing fuel
skids where two control valves were previously used.
The valve is available in 1-inch, 2-inch, and 3-inch ANSI
flange sizes to provide precise control for a range of gas
turbine applications. Selection of the valve size and flow
coefficient (Cv) is based on the specific site, and on turbine
gas flows and pressures. The flow coefficients for each valve
size are listed in Table 2-1.
Table 2-1 Flow Coefficients (Cv) for 1”, 2”, & 3” Valves
Valve Size Flow Coefficient
1-inch 2 Cv
1-inch 5 Cv
2-inch 12 Cv
2-inch 25 Cv
2-inch 30 Cv
3-inch 60 Cv
The fuel flow characteristics of the valves are approximately

linear, as shown in Figure 2-1 on page 2-2. Table 2-2 gives
the numerical data for each Cv curve plotted in Figure 2-1.
Table 2-2 Flow Coefficient (Cv) Data
Percent Open Cv = 12 Cv = 25 Cv = 30 Cv = 60
0% 0.1 0.1 0.2 0.2
5% 0.1 0.2 0.3 1.2
11% 0.3 0.4 0.6 3.4
22% 1.0 1.7 2.2 8.5
33% 2.1 3.5 4.6 14.8
44% 3.5 5.8 7.7 22.0
55% 5.4 8.9 11.9 29.9
66% 7.5 12.4 16.5 38.2
77% 10.1 16.7 22.2 45.7
88% 12.5 20.6 27.5 53.0
100% 14.8 24.4 32.6 59.0
2-2 Product Description
60.0
Cv = 60
50.0 Cv = 30
Cv = 25
40.0 Cv = 12
Flow Coefficient, Cv
30.0
20.0
10.0
0.0
0 20 40 60 80 100
Percent Open
Figure 2-1 Valve Flow Characteristic, Model 4280
The following sections provide further descriptions of the
valve, actuator and controller systems.
Mechanical Fuel Valve Model 4280

The model 4280 valve includes the Rotary Fuel Gas Valve
and the Rotary Actuator, as shown in Figure 2-2. The
actuator, yoke, and coupling assemblies are identical for the
1-inch, 2-inch, and 3-inch valve sizes.
The fuel valve is a balanced rotary design with precise
resolution and flow control across a wide range of turbine
operation, from ignition to full power.
The valve body is rated for applications with 1000 psig supply
pressure and is designed with standard ANSI Class 600
raised-face (RF) flanges.
January 27, 1998

Actuator
and Yoke
(common)
Coupling
Machined
Slot Dowel
Pin
1” Fuel Valve
2” Fuel Valve
Vent
3” Fuel Valve
Figure 2-2 1”, 2”, and 3” Rotary Fuel Valves and Actuator
The common actuator has a digitally controlled stepper motor
and drives through a precision spur gear. Position feedback is
provided by a digital encoder. The actuator can produce up to
50 Newton-meters of torque, and will travel its full rotation of
60˚ in 250 msec.
The actuator mechanical stops are located within the
actuator head. The fully open position of the valve is reached
when the valve actuator is rotated in the clockwise direction
to the mechanical stop (while looking down onto the top of
the actuator). The fully closed position is reached when the
valve actuator is rotated in the counter-clockwise direction to
the mechanical stop. A position indicator is provided on the
coupling to give the approximate position of the valve
actuator. Refer to Position Indicator on page 5-3 for more
information.
The positions of the mechanical stops in the actuator are

checked using the precision dowel pin and precision slot
machined into the coupling between the actuator and valve
assemblies, as shown in Figure 2-2. Refer to Actuator
Mechanical Stop Setup on page 5-1 for more information.
The actuator enclosure is designed for use in hazardous
environments (Class I Division 1, Groups C & D,
explosion-proof), and has been certified by CSA.
The actuator is O-ring gasketed and suitable for NEMA Type
4 indoor and outdoor use.
Electronic Actuator Controller Model 8412

Control System Each fuel valve size uses the same electronic control system,
which is controlled by a high-speed microprocessor. An
EEPROM is provided for storage of the configured
parameters.
The control system receives its demand position signal
through a 4-20 mA input. This signal is converted to a 12-bit
digital value using an analog-to-digital converter, and is then
compared to the current position of the actuator. The current
position signal is obtained from a 12-bit absolute optical
encoder, which gives an absolute angular position with a
resolution of 0.022˚. The error signal is calculated within the
system based on the difference between the current position
and the desired position. The control system then determines
the number of steps required to move from the current
position to the desired position and steps to the appropriate
point. The system uses an acceleration/deceleration profile
that optimizes speed and torque.
The control system is designed to freeze the valve in place if
there is a failure of either the DC power supply or the
command signal set point (configurable).
The controller enclosure is a NEMA 4 design with a sealed
door. The enclosure is not intended for outside service and
must be located in an area classified as safe.
January 27, 1998

Nonisolated A 4-20 mA position feedback signal is provided by the

controller and may be used to monitor the fuel valve position.
Output
Feedback
Note: This position feedback loop is powered by the controller (24

Vdc) and is not isolated. It is recommended that the user
provide in-line fuses and electrical isolation when using this
signal.
Controller A system FAULT relay is provided to indicate a complete

system failure. A system ERROR relay is provided to indicate
Status Relays an unusual operating condition. Refer to Controller Status
Relays on page 5-14 for more information.
Specifications The specifications for all the Rotary Fuel Valve sizes and the
Controller are listed in Appendix A.
This page intentionally left blank.
January 27, 1998

Product Information 3-1
Chapter 3: Product Information
Receiving Upon receipt, the equipment should be carefully inspected for

damage which may have occurred during shipping. Any
damage should be immediately reported to the freight carrier
and to Amot Controls.
The valve/actuator and controller are packed in separate
crates.
Inspection Carefully unpack the equipment taking care to save the

shipping carton and any packing material, should it be
necessary to return the unit to Amot Controls. Verify that the
items on the packing list agree with the order.
The flow coefficient (Cv) of the valve is specified on the
nameplate and should be marked on the outside of the crate.
Storage If the actuator will not be installed immediately, it should be

stored in a clean, dry, noncorrosive environment. The storage
temperature for the valve and actuator must not be less than
-40˚F (-40˚C) and not more than 212˚F (100˚C). The storage
temperature for the controller must not be less than -4˚F
(-20˚C) and not more than 158˚F (70˚C).
Returned In the event the valve or controller requires service, obtain a

Returned Material Authorization (RMA) number from Amot
Material Controls [phone (510) 236-8300, FAX (510) 234-9950] before
Authorization returning any equipment for repair. To facilitate quick return
and handling of your product, include the RMA number,
company name, address, original purchase order number,
and a brief description of the problem. A form is included in
Appendix G for this purpose. Package the product with the
RMA number indicated on the exterior of the package and
send to:
Amot Controls
401 First Street
Richmond, CA
94802-2904
3-2 Product Information
Nameplate A nameplate, as shown in Figure 3-1, which includes a model

code, flow coefficient (Cv), and serial number is attached to
Data and each valve body. A separate nameplate is found inside the
Product Model 8412 Actuator Controller with similar data.
Identification
106915
Figure 3-1 Rotary Fuel Valve Nameplate
Note: When ordering parts or requesting information or service

assistance, please provide all nameplate and label
information.
Model and Part Table 3-1 summarizes the model numbers used for the
Numbers
Table 3-1 Model Numbers
System/Component Model No. Notes
Fuel Valve 4280 See coding below.
Actuator Controller 8412 See coding below.
January 27, 1998

Fuel Valve Model Example:

Code
Model Code: 4280 F 1 A - RHF4
Basic Model No. Special

Requirements
RHF (Revision Level)
Design Level
Enclosure
Code
1 NEMA 4 & 7
Non-Approved
2 NEMA 4 & 7;
CSA Class 1, Div. 1,
Grp. C & D
Actuated Valve
CodeHousing Type
A 2", ANSI Class 600, Steel, linear trim, 12 Cv
B 2", ANSI Class 600, Steel, linear trim, 25 Cv
C 2", ANSI Class 600, Steel, linear trim, 30 Cv
D 3", ANSI Class 600, Steel, linear trim, 60 Cv
F 1", ANSI Class 600, Steel, linear trim, 2 Cv
G 1", ANSI Class 600, Steel, linear trim, 5 Cv
L 2", ANSI Class 600, Stainless Steel, linear trim, 12 Cv

M 2", ANSI Class 600, Stainless Steel, linear trim, 25 Cv
N 2", ANSI Class 600, Stainless Steel, linear trim, 30 Cv
P 3", ANSI Class 600, Stainless Steel, linear trim, 60 Cv
T 1", ANSI Class 600, Stainless Steel, linear trim, 2 Cv
U 1", ANSI Class 600, Stainless Steel, linear trim, 5 Cv
Actuator Example:
Controller
Model Code Model Code: 8412 E 1 4 - (---)
Basic Model No. Special Requirements

(if any)
Revision Level Enclosure
Code
Power Supply Input 4 NEMA 4
Code
1 24 Vdc
Table 3-2 provides ordering information and a part number for

the components of the Rotary Fuel Valve system.
Table 3-2 Ordering Information
Item Part No. Description
Actuator Controller 60-200620-024 24Vdc, NEMA4, export packing,
CSA
Gas Valve, 2 Cv 20612X16F 1" valve & accessories kit in
20612X17F export packing, CSA
Gas Valve, 5 Cv 20612X16G 1" valve & accessories kit in
20612X17G export packing, CSA
Gas Valve, 12 Cv 60-200617-012 2" valve with flange & accesso-
ries kit in export packing, CSA
Gas Valve, 60 Cv 60-200622-030 3" valve & accessories kit in
export packing, CSA
Spare Fuse and 60-200610-SPR See Table 3-3 below.
Connector Kit
Table 3-3 lists the contents of the Fuse and Connector kit.
Table 3-3 Spare Fuse and Connector Kit (60-200610-SPR)
Qty Description
Fuses
1 100 mA, fast acting, IEC type
1 10 A, fast acting, CSA/UL type
1 600 mA, Slo-Blo, CSA/UL type
Field Connectors
1 Plug for connector, 2-pin, Weidmueller
12 Mounting block BB2 for Weidmueller connectors
7 Label strip for Weidmueller connectors
Valve Cable Entry
1 Cable entry gland (CG5075)
1 Cable entry locking nut
Relay
1 Relay, 1 Form A, 5V
January 27, 1998

Flange and Table 3-4 lists the parts included in the RJR flange and
accessories kit for the 2-inch valve.
Accessories Kit
Table 3-4 RJR Flange and Accessories Kit for 2” Valve
(20190X003)
QTY Description
2 2" x ANSI Class 600 RF weld neck flanges, A105 carbon
steel with schedule 80 weld preparation
17 5/8–11 (UNC) x 4" long, hex head, grade 8 bolts
17 5/8–11 (UNC) Grade 7 hex nut and lock washer
17 lockwasher for 5/8" bolt
2 CG5075 Appleton cable grip (3/4" NPT x 1/2" grip)
4 2CG3G Flexitallic gaskets with flexite super fill and carbon
steel centering ring
2 U-bolt, 1/2–13 UNC
5 1/2–13 UNC hex nut
5 lockwasher for 1/2" bolt
The accessories kits for the 1-inch and 3-inch valves do not
include companion flanges. The part number for the 1-inch
valve is 20351X002, and for the 3-inch valve is 20350X002.
These kits are normally shipped with the valves.
January 27, 1998

Installation 4-1
Chapter 4: Installation
Precautions Amot Controls designs, manufactures, and tests its products

to meet many national and international standards. However,
for these products to operate within their normal
specifications, they must be properly installed, used, and
maintained.
Warning! The following instructions must be adhered to and

integrated with the user’s safety program when
installing, using, and maintaining Amot Controls
products.
■ Read and save all instructions prior to installing, operating,

and servicing this product.
■ Follow all warnings, cautions, and instructions marked on
and supplied with the product, including those within this
manual.
■ Inform and educate your personnel in the proper
installation, operation, and maintenance of the product.
■ Install the equipment as specified within the installation
instructions provided by Amot Controls, and by the
applicable local and national codes.
■ Connect all products to the proper electrical source.
■ Handle, move, and install each product using the
appropriate number of personnel and the appropriate
moving devices and equipment (dolly, forklift, crane).
Failure to do so could cause serious personal injury.
■ To ensure proper performance, use qualified personnel to
install, operate, update, tune, and maintain this product.
■ When replacement parts are required, ensure that the
qualified service technician uses only replacement parts
specified by Amot Controls. Unauthorized substitutions
may result in fire, electrical shock, other hazards, or
improper equipment operation.
■ Ensure that all actuator protective covers are in place
(except when maintenance is being performed by qualified
personnel) to prevent electrical shock, personal injury, or
damage to the actuator.
4-2 Installation
■ Remove the covers only when explosion-proof standards

permit.
Caution: Take care not to trap wiring between the actuator body and
top cover faces when installing the actuator top cover.
Grounding the high power motor drive cabling to the actuator
case could damage the electronic controller circuits.
■ Hermetically seal all open and used conduit glands on the

fuel valve and controller to prevent the ingress of dirt and
corrosive products.
■ If you do not fully understand the instructions, contact your
local Amot Controls representative for clarification.
Warning! To avoid a shock hazard or gas explosion, installation

and servicing must be performed only by qualified
personnel. De-energize all sources of power BEFORE
removing the actuator cover. KEEP THE ACTUATOR
COVER TIGHT WHEN CIRCUITS ARE ALIVE. Failure to
follow these precautions may result in serious injury or
death.
Power and ■ Power to the control box (8412) must be 24 Vdc (18-32
Vdc).
Input
■ Power consumption is 125 watts (VA) maximum.
Requirements ■ There are no 24 Vdc power supply connections to the
valve.
■ The demand position signal must be within the range of
4-20 mA.
Caution: Before power is applied to the unit, make sure that the
voltage polarity is correct. Failure to do so will result in a
blown fuse.
January 27, 1998

Installation 4-3
Fuel Valve Note that the gas flow direction is indicated by an arrow on
the 2-inch and 3-inch valve bodies, as shown in Appendix B.
Before installing the valve, make sure that it is correctly sized

(Cv) and is suitable for the intended application with respect
to environmental conditions and the voltage and frequency of
available line power. If you are unsure of the suitability of this
equipment for your installation, consult Amot Controls before
proceeding.
Warning! Amot Controls requires the use of a traditional skid

design that uses two independent block/shutoff valves
(“double block and bleed”) in series with the gas control
valve. The 4280 fuel valve will flow (leak) up to 0.5% of
rated flow in the closed position.
The valve/actuator may be installed in either the vertical or

horizontal plane and should normally be supported so that its
weight is not transferred to the connecting piping.
If the valve is anchored to a solid skid surface, movement and
expansion of any fixed piping connected to the valve must be
considered. It is recommended that flexible piping be used
whenever possible.
Warning! The valve MUST BE REMOVED FROM THE INSTALLED

LOCATION before any attempt is made to disassemble
the actuator from the valve.
The 1-inch valve is mounted on the skid using two bolts which
screw into the valve body. U-bolts are supplied to clamp the
2-inch and 3-inch valves to the skid. Appendix E provides
mounting details for each valve size.
Flexitallic gaskets are recommended for flange seals. Check
that the flange faces are clean during final assembly. Torque
all flange bolts evenly to the values listed in Table 4-1.
4-4 Installation
Table 4-1 Flange Bolt Torque Values

Valve Size Number of Bolts Bolt Size Torque (ft-lbs)
1-inch 4 5/8”–11 60
2-inch 8 5/8”–11 105
3-inch 8 3/4”–10 195
Fuel Valve Vent If the valve is not to be vented to another area, fit a short
Connection length of stainless steel pipe to the vent outlet, turned down
to prevent the ingress of dirt or foreign bodies.
When possible, the valve should be mounted such that the
vent line flows down and away from the valve. This will allow
the use of gravity to prevent a build-up of condensation fluids
in the vent line over time.
Warning! If a cartridge O-ring seal or the primary rotor seal fails,

fuel will leak out of the vent. Therefore, the vent must
discharge into an area classified as hazardous (Class I
Division 1, or Class I Division 2), or to the outside air if
local codes permit.
Cable Entry If the valve is installed in an explosion-proof area, an

Gland approved flameproof entry device (not provided by Amot
Controls) must be used. The explosion-proof conduit must
also be sealed within 0.5m of the actuator.
Otherwise, the 3/4" NPT cable grip gland supplied with the
valve may be used.
Filters A gas filter is not included in the Model 4280 Fuel Valve.
Because of the tight clearances within the valve, a 10-micron
full-flow filter should be installed by the user upstream of the
valve. It is also recommended that a “last chance” 200-micron
filter be installed at the inlet flange of the valve.
January 27, 1998

Installation 4-5
Model 8412 For optimum dissipation of excess heat, the control box
should be mounted in a vertical position with a minimum 0.5
Actuator inch clearance at the rear of the enclosure, as shown in
Controller Figure 4-1.
Model
Mounting Wall 8412
Controller
0.5"
Figure 4-1 Control Box Mounting
4-6 Installation
Cabling Figure 4-2 identifies the locations and functions of the cables
required for the Rotary Fuel Valve and Controller. Figure C-2
Requirements on page C-2 also shows the locations of the cables and
provides further details.
DEMAND FEEDBACK
Position Position Signal
Set Point (for monitoring)
4-20 mA 4-20 mA
Control Feedback
Cable Cable
Power Supply
Controller (24 Vdc)
Power
Cable
Position Motor
Cable Cable
Serial Encoder Stepper Motor Drive
Position Feedback (high noise-emitting cable)
Valve Actuator
Fuel Valve
Note: Figure C-2 on page C-2 provides

further cabling details.
Figure 4-2 System Cabling Requirements

The following sections give the specifications and
requirements for CE Mark compliance for each cable.
Control and The control and feedback cables shall be Belden 8723 or
Feedback Cables equivalent. Shielded cabling is used to reduce the effects of
emissions and improve immunity to externally applied
electrical phenomena.
The control cable is a critical 4-20 mA cable. It is strongly
recommended that a dedicated cable be used for this
purpose. There is no restriction on cable length.
January 27, 1998

Installation 4-7
Additional requirements for these cables are as follows:

■ 4 conductor
■ 2 twisted pairs
■ Overall shield
■ 22 AWG
Motor Cable The motor cable shall be Alpha 5610B2002E or equivalent.

This cable is a high current, pulsing 5-amp power line. The
cable run is limited to 300 feet. Table 4-2 list the minimum
American Wire Gage (AWG) requirements per cable length.
Table 4-2 Motor Cable Length vs. AWG
Cable Length Minimum AWG
< 66 ft. (20 m) 18
< 164 ft. (50 m) 16
< 328 ft. (100 m) 14
The motor cable is an unshielded assembly since the use of a

shielded cable would add distributed capacitance and
adversely affect the actuator stepper motor performance. It is
recommended that this cable be run in a separate conduit (to
reduce noise emissions), and separated from all other
cables.
Additional requirements for this cable are as follows:
■ 4 conductor
■ 2 twisted pairs
Position Cable The position cable shall be Alpha 1898/5C or equivalent.

Shielded cabling is used to reduce the effects of emissions
and improve immunity to externally applied electrical
phenomena.
This cable is a RS422 serial line and is best limited to 300
feet. The position cable should not be combined with the
motor cable.
Additional requirements for this cable are as follows:
■ 5 conductor
■ Overall shield
■ 18 AWG
4-8 Installation
Power Cable The 24 Vdc power supply cable must be rated for 20 amps. A
dedicated circuit breaker should be used for this power
supply.
January 27, 1998

Configuration and Operation 5-1
Chapter 5: Configuration and Operation
Actuator The actuator mechanical bottom and top stops located within
the actuator head are set at the factory for the maximum
Mechanical stroke of the fuel valve. Controller setup and calibration at 4
Stop Setup and 20 mA is made relative to the actuator mechanical stops.
Caution: Check the actuator mechanical stop positions prior to

Controller setup and calibration. Any adjustments of the
mechanical stops should be done with the controller power
off.
The position of the mechanical bottom stop is checked using

the precision dowel pin and the precision slot machined into
the coupling between the actuator and valve assemblies. The
distance between the dowel pin and the end of the slot when
the valve is at the bottom stop is initially set at 0.005 inch. The
closed position datum for the valve is shown in Figure 5-1.
Coupling
Precision
Machined Slot
0.005”
(typical) Precision Dowel Pin
Note: Dowel pin and slot shown in closed-flow position.
Figure 5-1 Precision Dowel Pin and Machined Slot

If it is necessary to reposition the actuator mechanical stops,
a small clearance (0.005 inch) is required between the
precision dowel pin and the end of the machined slot to
ensure that the actuator cannot apply load to the dowel pin.
The dowel pin is NOT intended for precise positioning of the
fully open mechanical top stop. The fully open position is set
electronically during the configuration procedure.
5-2 Configuration and Operation
The maximum stroke of the valve actuator is approximately

70˚, but depends on the exact settings of the mechanical
stops. The operational range of the valve stroke from
minimum to maximum flow is 60˚. The mechanical top stop
should be positioned at 62˚. Figure 5-2 shows a typical flow
characteristic curve for the fuel valve and the corresponding
valve trim orifice positions at reference points 1 through 5
on the curve.
Typical Fuel Valve Flow Characteristic -2˚

Flow
4
100%
1
5
Mechanical Bottom Stop
Do not operate
3 in this region 0˚
Dead
Zone
2
0.5% 2 Flow Crack Point

1
-2˚ 0˚ Flow 30˚ 60˚ Valve Trim Position 30˚
Crack
Point
3
50% Open
Flow through trim orifices
60˚
100% Flow
>60˚
Do Not Operate In This Region

Figure 5-2 Typical Flow Characteristic and Corresponding Valve Trim Orifice Positions
January 27, 1998

There is a dead zone in the valve flow characteristic at the

closed position where the trim flow path is at a minimum
(reference point 1). The actual fuel flow through the valve in
this region is essentially trim leakage. During setup and
calibration, this region is identified as a negative degree
position (such as –1.1˚).
The flow crack point (reference point 2) is the point at which
the valve begins to open. The exact absolute encoder count
at the flow crack point is normally identified at the factory and
written on a label inside the actuator. When provided, this
count value may be used to calibrate the 0%, 4 mA, low
actuator position to coincide with the flow crack point (see
Manual Setup (Alternative) on page 5-10). If this value is not
provided, it may be necessary to find the flow crack point by
flowing air through the valve.
Note: The absolute encoder position values are fixed with respect
to the valve trim position, and are independent of the set
point calibration. The only time that the absolute encoder
values change with respect to the flow crack point is if the
encoder is removed from the actuator.
Reference point 3 corresponds to a valve position of 30˚ and

a stroke of 50%.
The 100% flow condition is reached at a valve position of 60˚
(reference point 4). Do not calibrate the fully open position
at a valve stroke greater than 60˚. At strokes above 60˚, the
flow characteristic decreases and provides for less flow
(reference point 5). The mechanical top stop should be
positioned at 62˚.
Position A position indicator on the coupling shows the approximate

position of the valve actuator. The approximate degrees of
Indicator valve rotation for each graduation on the indicator are given in
Figure 5-3 and Table 5-1. (These values are not shown on the
valve.) The approximate location of the fully open, 100% flow
position (60˚) is shown in the figure.
Note: There is not a graduation which corresponds to the fully

open, 100% flow position (60˚).
The valve opens in the clockwise direction (while looking

down onto the top of the actuator).
Open
position indicator
on coupling
(open) (closed)
66˚ 0˚
49.5˚ 16.5˚
60˚ 33˚
(100% flow) Note: These values are not
marked on the valve.
Figure 5-3 Valve Position Indicator Graduations

For a calibrated valve, the valve position indicator graduations
correspond approximately to the valve stroke percentages
listed in Table 5-1.
Table 5-1 Valve Position for each Graduation
Degrees of Rotation Calibrated Stroke % Notes
0˚ 0% closed
16.5˚ 27.5%
33˚ 55%
49.5˚ 82.5%
60˚ 100% no graduation
66˚ Over Range
January 27, 1998

Operating The Actuator Controller has two operating modes: SETUP

and RUN. The SETUP mode is used to configure the system,
Modes as discussed in Configuration on page 5-7. The RUN mode is
used to operate the system, as discussed in Automatic
Operation on page 5-12.
The operating mode is selected using switch 1 (S1) on the
Printed Circuit Board (PCB) assembly shown in Figure C-1
on page C-1. Switch 1 can be placed in either the RUN or
CONFIG position. The proper switch settings for
configuration and operation of the system are discussed in
the Configuration and Automatic Operation sections.
The current operating mode of the system is indicated by the
LCD display and LED indicator lights described in User
Interfaces, below.
Caution: Before power is applied to the unit, make sure that the
voltage polarity is correct. Failure to do so will result in a
blown fuse.
DIP Switch To configure and operate the controller, the DIP switches
(SW1) on the stepper motor drive module must be set as
(SW1) Settings shown in Table 5-2. This is the only valid configuration for the
DIP switches.
Table 5-2 DIP Switch Settings for SW1
DIP Switch Setting
1 off
2 on
3 on
4 off
5 off
6 off
User Interfaces The user interfaces for the Rotary Fuel Valve consist of a
20-character x 2-line backlit LCD display, two LED indicator
lights (red and green), and four push buttons. Figure D-1 on
page D-1 shows the locations of the LCD display, LEDs, and
push buttons.
Push Buttons The push buttons are labeled:

■ OPEN (RAISE)
■ CLOSE (LOWER)
■ SELECT
■ ESC
LCD Display The LCD display is divided into three main areas. In the
SETUP mode, these three areas are:
■ current actuator mode of operation, SETUP,
■ current menu sequence, and
■ current menu option.
In the RUN mode, the three LCD display areas are:
■ current actuator mode of operation, RUN,
■ current error level, and
■ parameter display:
S(et point) ##.##% V(alve position) ##.##%
LED Indicators The red and green LED indicators are used to confirm the
current mode of operation and to indicate any errors, as
shown in Table 5-3.
Table 5-3 LED Indications
LED Condition Indication
Green on, Red off Automatic Operation; no errors
Green on, Red flashing Automatic Operation; set point error
Green on, Red on Automatic Operation; valve position error
Green flashing, Red off Setup Mode
January 27, 1998

Configuration The Rotary Fuel Valve is configured with the controller in the
SETUP mode. The actuator can be manually positioned in
this mode.
To configure the system, switch 1 (S1) on the PCB should be
placed in the CONFIG position. Refer to Figure C-1 on
page C-1 for the switch location and setting.
On entering SETUP mode, the user will be at the start of the
main menu sequence shown in Figure 5-4 on page 5-8. The
main SETUP modes shown in Figure 5-4 are discussed in
subsequent sections.
Note: In the SETUP mode, the ESC key returns the user to the start
of the main menu sequence. Any changes to displayed
values that have not been saved with the SELECT key will be
ignored.
Controller The controller software version (such as 2.30D) is displayed

Software Version on the LCD upon entering the SETUP mode.
Manual Position From the main menu, select MANUAL POSITION. The OPEN
and CLOSE keys will cause the actuator to rotate
appropriately. Motor speed will increase after a key has been
held down for 2 seconds.
In this mode, the angular position information (POS: ##.##
degrees) is valid only if the valve has been properly
configured. The encoder absolute position count, shown as
RAW: ##### (0 to 4095), is displayed and is independent of
calibration. No restriction is placed on actuator movement.
The actuator may be driven into the end stops. Pressing
SELECT or ESC will exit this mode of operation.
Auto Setup The AUTO SETUP sequence calibrates the actuator for the
open and closed set points and control inputs.
Fully Closed From the main menu, select AUTO SETUP. The message
Position “DRIVING TO END STOP” will be displayed, and the actuator
will move to the fully closed end stop. This end stop is set at
the factory to be -2˚ past the minimum flow point.
When the end stop is reached, “MIN SP -2.00 DEG” will be
displayed. The OPEN and CLOSE keys are then used to
move the actuator to the desired position. The current valve
LOWER
SETUP MAIN SETUP MANUAL MOVE
MANUAL POSITION SELECT USE RAISE/LOWER SELECT
RAISE LOWER
SETUP MAIN
AUTO SETUP SETUP AUTO SETUP
SELECT DRIVING TO END STOP
1
SELECT SELECT
SETUP AUTO SETUP SETUP AUTO SETUP
RAISE LOWER 2 MIN SP –2.00 DEG 6 VALVE CONFIGURED
SELECT
SETUP AUTO SETUP
SAVE SETTING
3 MAX SP 60.00 DEG SELECT
SETUP MAIN
MANUAL SETUP SETUP MAN SETUP
SELECT MOVE TO CLOSED POS
4
SELECT
SETUP MAN SETUP
RAISE LOWER 5 MOVE TO OPEN POS
SELECT SELECT
SETUP MAN SETUP
SAVE SETTING
VALVE CONFIGURED
6
SETUP MAIN
CONTROL ACTION
SELECT SETUP CONTROL ACTION
SAVE SETTING
FORWARD
RAISE LOWER SELECT
RAISE LOWER
SETUP CONTROL ACTION
REVERSE
SETUP MAIN
HYSTERESIS SETUP HYSTERESIS
SELECT SAVE SETTING
RAISE LOWER SELECT
7
SETUP MAIN
SET POINT FAIL
SETUP SET POINT FAIL ACTION
RAISE SELECT SAVE SETTING
GO TO MIN POSITION
RAISE LOWER SELECT

GO TO MAX POSITION
See Notes on next page. RAISE LOWER
REMAIN STATIONARY
Figure 5-4 Controller Setup Sequence
January 27, 1998

Figure 5-4 Notes:

1. At this point, the actuator will be driving towards the “fully
closed” point until it reaches the end stop.
2. Position the valve slightly off the end stop by setting the
SP to -1.0˚ using the OPEN and CLOSE keys. Use a
calibrated current source to input the “fully closed” set
point signal (normally 4 mA) before pressing SELECT.
3. Use a calibrated current source to input the “fully open” set
point signal (normally 20 mA) before pressing SELECT.
4. Position the valve (using the OPEN and CLOSE keys) and
input the “fully closed” set point signal before pressing
SELECT.
5. Position the valve (using the OPEN and CLOSE keys) and
input the “fully open” set point signal before pressing
SELECT.
6. This screen confirms that the actuator is configured.
7. Use the OPEN (RAISE) and CLOSE (LOWER) keys to
adjust the hysteresis setting. This is adjustable in the
range 0 to 9% in 0.05% steps.
position is displayed in degrees. A negative value indicates a

position at less than minimum flow. Set the SP to -1.0˚. The
fully closed set point signal should then be applied (minimum
4 mA). Pressing SELECT enters these values into memory.
Fully Open The valve will not move from the fully closed point during this
Position sequence. The display will then read “MAX SP 60.00 DEG,”
which corresponds to the desired fully open point. The
displayed value may be raised or lowered using OPEN and
CLOSE. The fully open set point signal should now be
applied (maximum 20 mA). Pressing SELECT enters these
values into memory.
A “CONFIGURATION ERROR” message will be displayed if
the input signal is not changed between the minimum and
maximum set points (that is, if 4 mA is input for both the fully
closed and fully open positions).
The message “VALVE CONFIGURED” will be displayed
indicating the successful completion of this sequence.
Pressing SELECT exits the display and returns to the main
menu sequence.
Manual Setup The MANUAL SETUP sequence also calibrates the actuator
(Alternative) with open and closed set points and control inputs. This
procedure is slightly longer, and provides for calibration of the
closed position at the valve flow crack point.
Fully Closed From the main menu, select MAN SETUP. The message
Position “SET CLOSED POS: #####” will be displayed. The encoder
absolute position count is available in this mode. Use OPEN
and CLOSE to move the actuator to the desired fully closed
position. The fully closed set point signal should then be
applied (minimum 4 mA). Pressing SELECT enters the
values into memory.
Fully Open The message “SET OPEN POS: #.## degrees” will be
Position displayed. Use OPEN and CLOSE to move the actuator to
the desired fully open position (normally 60.0˚). The fully
open set point signal should then be applied (maximum 20
mA). Pressing SELECT enters the values into memory.
The message “VALVE CONFIGURED” will be displayed
indicating the successful completion of this sequence.
Pressing SELECT exits the display and returns to the main
menu sequence.
Control Action The CONTROL ACTION sequence programs the actuator for
forward or reverse control action.
From the main menu, select CONTROL ACTION. The
message “CONTROL ACTION” will be displayed, along with
the current mode of operation, either “FORWARD” or
“REVERSE.”
Use OPEN (RAISE) and CLOSE (LOWER) to toggle between
the two options. Pressing SELECT enters the chosen option
into memory and returns to the main menu sequence.
Note: Normally, a FORWARD action provides for the safest

operation of the actuator because a lost command signal
tends to close the valve (see Set Point Fail on page 5-11).
January 27, 1998

Hysteresis The HYSTERESIS sequence programs the controller with a

hysteresis value.
From the main menu, select the HYSTERESIS option. The
message “HYSTERESIS” will be displayed, along with the
current hysteresis value. Use OPEN (RAISE) and CLOSE
(LOWER) to raise or lower the displayed value in 0.05%
increments in the range 0.00 to 9.00%. Holding down a key
for 2 seconds will cause the displayed value to change
rapidly. Pressing SELECT enters the chosen option into
memory and returns to the main menu sequence.
Note: Normally, a hysteresis value less than 0.2% is desirable.
Set Point Fail The SET POINT FAIL sequence programs the actuator with
the required action in the event of a set point signal failure,
defined as a set point signal outside (above or below) the
configured maximum and minimum values.
From the main menu, select the SET POINT FAIL option. The
message “INPUT FAIL” will be displayed, along with the
current active option. Use OPEN (RAISE) and CLOSE
(LOWER) to scroll through the available options:
■ REMAIN STATIONARY: maintain current position
■ GO TO MIN POS: Move valve to the fully closed position
■ GO TO MAX POS: Move valve to the fully open position
Pressing SELECT enters the chosen option into memory and
returns to the main menu sequence.
Warning! Always test the failure action of the valve after setup is
complete.
Automatic The Rotary Fuel Valve is operated with the controller in the
RUN mode. Switch 1 (S1) on the PCB should be placed in
Operation the RUN position. Refer to Figure C-1 on page C-1 for the
switch location and setting.
A functional diagram showing the system layout is given in
Figure 5-5.
COMMAND FEEDBACK
Position Position Signal
Set Point (for monitoring)
4-20 mA 4-20 mA
Controller Power Supply

(24 Vdc)
Encoder Position Stepper Motor Drive

Feedback (high noise-emitting cable)
Valve Actuator
Fuel Valve
Figure 5-5 System Layout for Control of Fuel Valve
Power-Up When power is applied to the unit, it will immediately attempt

to reduce any error between the valve position and the input
set point. The top line of the LCD display will show the current
mode of operation (RUN) and any errors. If there are no
errors, the display will read “RUN NORMAL.” The bottom line
of the LCD will display the command set point and the current
actuator position in terms of percent open. Zero percent
corresponds to the fully closed point configured by the user.
Normal During normal operation, the controller will attempt to reduce

Operation any error between the set point and the current position
(when the error is greater than the hysteresis value).
In response to a measured error, the controller generates a
velocity profile, which consists of an acceleration region, a
constant velocity region, and a deceleration region. The
velocity profile is calculated to optimize movement of the
valve to the desired position. If the set point changes before
the movement is complete, a new velocity profile is
January 27, 1998

calculated. The set point is sampled and the velocity profile

calculated every 5 msec.
DC Power Failure The actuator will hold its current position when 24 Vdc power
is removed for any reason. The gas forces on the flow
elements are less than the detent torque of the unpowered
stepper motor.
Set Point Failure The limits of motion of the valve, set during configuration, are
stored in multiple, error-checked locations in the nonvolatile
memory of the controller. In response to a set point signal
outside of the configured range, the controller will respond as
configured (see Set Point Fail on page 5-11).
The presence of a set point error is indicated by a flashing
red LED and an LCD message indicating the nature of the
error. The displayed message will be either “SP HIGH” for a
high set point value, or “SP LOW” for a low set point value.
The system ERROR relay contacts will open.
If the set point moves back inside the configured range,
normal functioning will resume immediately.
Valve Position The valve position limits are stored in the same manner as
(Encoder) Failure the maximum and minimum set points. If the controller
detects that the valve position has moved outside the
configured range, it will hold the current valve position,
illuminate the red LED continuously, and display a “VALVE
ERR” message on the LCD. The system ERROR relay
contacts will open.
Similarly, if the controller detects an encoder serial
communications loss or error, it will hold the current valve
position, illuminate the red LED continuously, and display a
“ENCODER ERR” message on the LCD. The system ERROR
relay contacts will open. If the position signal is restored,
normal functioning will resume immediately.
When an encoder failure is detected, the controller will pulse
the 4-20 mA feedback signal at +/-1.0% at the rate of 0.25
Hz.
EEPROM If an unrecoverable data corruption occurs, the red LED will

Corruption illuminate continuously and a “DATA ERROR” message will
be displayed on the LCD. The valve configuration must be
reentered by entering the SETUP sequence. The
configuration data is stored in multiple, individually checked
blocks. If any one block becomes corrupted, the data will be
copied from an uncorrupted block. This data recovery
process takes place without indication to the user.
Controller Status The 8412 Actuator Controller includes two error output relays
Relays which are energized (contacts closed) when the controller is
in a healthy state. These two relays (K1 and K2) are Aromat
DK-1a series with form 1a contacts rated at 10A @ 30 Vdc
(10A @ 250Vac). The relays are socketed to allow
replacement in the event they fail.
The ‘SYSTEM ERROR’ relay tracks the red light on the
control box. The contacts will open if there is an encoder
failure, valve position failure, set point failure, or configuration
error.
The ‘SYSTEM FAULT’ relay tracks the reset line on the
processor. This output indicates a processor crash or other
complete system failure. The ‘SYSTEM ERROR’ relay will
also de-energize under these conditions.
SYSTEM ERRORS are generally considered to be
recoverable, while SYSTEM FAULTS are considered
nonrecoverable. Since the error outputs are nonlatching, the
relays will return to the healthy state when the error is
cleared.
January 27, 1998

Specifications A-1
Appendix A: Specifications
This appendix gives the specifications for the Rotary Fuel

Valve system.
Application: Direct Control of Natural Gas Turbine Fuel
■ Valve Model No.: 4280
(See Fuel Valve Model Code on page 3-3.)
■ Actuator Controller Model No.: 8412
(See Actuator Controller Model Code on page 3-3.)
Table A-1 Actuator Specifications
No. Type Specification

1.0 Environmental – Valve and Actuator
1.1 Operating temperature -4 to 140˚F (-20 to 60˚C)
limits
1.2 Storage temperature -40 to +212˚F (-40 to +100˚C)
1.3 Actuator enclosure Designed for Class 1, Div. 1,
Group C and D; weather sealed
1.4 Vibration tolerance 5g (10–62 Hz)
IEC654-3, level 6 7g (63–3000 Hz)
2.0 Actuator, Mechanical
2.1 Drive type Stepper motor
2.2 Internal position Digital encoder
measurement
2.3 Valve shaft torque 37 lb-ft (50 Nm)
(momentary)
2.4 Operating range 60 degrees
2.5 Speed (open to close) 250 ms
2.6 Speed adjustment Fixed
2.7 Valve seat protection Adjustable mechanical stops at ends
of travel
2.8 Motor-to-shaft drive Precision gears (spur)
mechanism
2.9 Conduit entry Two, each 3/4" NPT
2.10 Overall dimensions See dimensional drawings (App. B)
2.11 Motor enclosure Aluminum/O-ring gasketed
material/seal
2.12 Exterior finish Anodize
2.13 Mounting of actuator On valve on standoffs; air gap above
valve
2.14 Motor/valve shaft coupling Antibacklash helical
type
A-2 Specifications

3.0 Actuator, Electrical
3.1 Loss of set point signal Hold last position/Go to 4 mA/Go to
20 mA (configurable by user)
3.2 Action on loss of power or Maintain current position
loss of feedback signal
3.3 Field wiring terminal type Weidemuller 2-part screw fastening
type
3.4 Wiring size range 14-20 AWG (see Table 4-2)
3.5 Motor protection Software
4.0 Actuator Performance
4.1 Positioning repeatability +/- 0.054%
4.2 Stepper motor error 0.066 degrees
4.3 Number of motor steps 1667 (in 60 degrees)
4.4 Maximum drive speed 100% travel in 250 ms
(both directions)
4.5 Temperature coefficient N/A (absolute encoder)
4.6 Measurement error N/A (absolute encoder)
4.7 Hysteresis (motor/gears) +/- 0.05% (10:1 gear ratio)
5.0 Actuator Controller
5.1 Line voltage 24 Vdc (18-32 Vdc)
5.2 Reserved
5.3 Electronic platform Digital
5.4 Power requirements Fused; 8 amps (125 VA maximum)
5.5 4-20 mA set point input 250 ohms
impedance
5.6 Enclosure/material NEMA 4/steel enclosure
5.7 Operating temp. limits 32 to 122˚F (0 to 50˚ C)
5.8 Storage temperature -4 to 158˚F (-20 to 70˚C)
5.9 Vibration tolerance 0.5g, 10 Hz to 3 KHz
IEC654-3
5.7 Cable(s), interconnect see Cabling Requirements on
page 4-6
5.8 Maximum distance from 300 ft (91.44 m)
valve to controller
5.9 Set point signal input 4-20 mA
5.10 Set point signal Floating zero restricted +/- 40 V
characteristics
5.11 Position transmitter signal 4-20 mA dc; nonisolated, fused
5.12 Position feedback signal Less than 5 msec
update time (serial)
5.13 4 mA point adjust 100% of full scale
5.14 20 mA point adjust 100% of full scale
5.15 Adjustable hysteresis 0.00 to 9.00% in 0.05% increments
5.16 Reverse acting User selectable
January 27, 1998

Specifications A-3

5.17 Auto/manual control Not switchable by operator (setup
mode only)
6.0 Operator Interface
6.1 Setup Push buttons/LCD display
6.2 Control indication LCD text + LED
6.3 Valve position indication Mechanical pointer on coupling and
4 digit BCD on LCD display
7.0 Valve, Mechanical
7.1 Valve type Rotary, balanced
7.2 Shutoff class ANSI Class I (not tight)
7.3 Shutoff leakage 0.5% typical
7.4 Valve body configuration Straight through
7.5 Controlled media Natural gas
7.6 Valve Flow Coefficient (Cv) Trim set options: 2, 5, 12, 25, 30, 60
7.7 Supply/Discharge Up to 1000 psi (69 bar)
working pressure
7.8 User connections ANSI Class 600 RF flange
7.9 Body material Carbon steel
7.10 Cartridge material Stainless steel/alloy (no sour gas)
7.11 Rotor material Stainless steel/alloy (no sour gas)
7.12 Stem material Stainless steel/alloy (no sour gas)
7.13 Inlet port material Stainless steel/alloy (no sour gas)
7.14 Value proof pressure 1450 psi (100 bar)
rating (individually tested)
7.15 Stem packing PTFE; double seal and vent
7.16 Packing adjustment None
7.17 Seals, other Viton
7.18 Exterior finish Cadmium plate (valve and yoke)
8.0 Weights
8.1 Actuator controller 22 lbs (10 kg)
8.2 Actuator 40 lbs (18 kg)
8.3 Valve/Actuator 1-inch: 108 lbs (49 kg)
2-inch: 110 lbs (50 kg)
3-inch: 240 lbs (109 kg)
A-4 Specifications
January 27, 1998

Installation Dimensions B-1
Appendix B: Installation Dimensions
Figure B-1 Installation Dimensions – Actuator Controller
B-2 Installation Dimensions
Figure B-2 Installation Dimensions – 1” Rotary Valve/Actuator
January 27, 1998

20.88
January 27, 1998

5.00
3.31
2.38
2.0
0.75 Dia.
8 holes 2.88
0.25 1.00
Welding Neck
3.625
6.50
• Dimensions in inches
• Not drawn to scale
Figure B-5 Dimensions – Class 600 Weld Neck Flange for 2” Valve
0.131
0.112
Guide Ring O. D.
+/- 0.031 Seal I. D.
+/- 0.016
Seal O. D.
+/- 0.016
• Dimensions in inches
• Not drawn to scale
• Material: #304 SS windings with Grafoil filler
Nominal Pipe Size Guide Ring O. D. Seal O.D. Seal I.D.

(inches) (inches) (inches)
1” 2.875 1.875 1.250
2” 4.375 3.375 2.750
3” 5.875 4.750 4.000
Figure B-6 Dimensions – ANSI Class 600 API 601 (Std) Spiral Wound Gasket
January 27, 1998

Wiring and Electronic Details C-1
Appendix C: Wiring and Electronic Details
Location of RUN/CONFIG switch (S1)
C20 CR3 R12

+ F4
C25 C19 C13
Y1 + CR4
U9
R16
R17
C32
CR2
C28
CR1
C29
+ R27 + C46
+C47 C14
F3 F2 F1 F5 Q1 C30 C26
U14 U11
Q2 R1
C23
RN1 R15
R13 U8 +
Q3
C24
C12
R9
+15V
U19 TP6 U12 C31 I
R2
R21
R22
C27
C18
VR1
C5
C7
C43
VR2
U10 TP5
C45
U7
R10 -15V
R8
R7
R6
R5
R4
R3
C10
C17 CR6 +
+
C42
RN3 RN2 CR5

C16
C11
C8 C9
S2 R20 C15
PROG TP3 TP4
AGND
R19 U15 VRET
R24
R25
S1 R23
RUN
CONFIG
AMOT CONTROLS CORP
COPYRIGHT ©1997
MADE IN U.S.A.
DGND
TP2 JP1
ROTARY ACTUATOR BOARD
U1 U2 C37 U16
66275L002 66275X2
REV 1 C1 C2 +
REV C41
TP1 LED1
+5V
C39
C38
C3
LED2
R18
U3 U17
C22
U20 U21
C5
C33
C21
U5
U5 J1
C44
C40
Y2
C34
C35 C36 RN4

U13
Figure C-1 Printed Circuit Board
C-2
8412E ASSEMBLY
Wiring Notes:
1. The green wire in the actuator case must be
connected to TB1 pin 1 on 66280X1. J1
66275X2 ROTARY ACTUATOR
2. J3 pin 5 on 66281X1 should not be connected. CONTROLLER ASSEMBLY
9
3. J10 and J11 relay contacts on 66281X1 are 8
January 27, 1998

rated at 10A 30V DC,10A 250 V AC, and are 7 External/Field Cables
energized healthy. 6
4. Additional cabling info is given on page 4-5. 5 Internal Connections
J2
J3
DB15M
DB9F
4
5. All installation wiring should meet the National 3
Electrical Code standards, as well as any 2
state and/or local standards. 1
+15V
-15V
N/C
N/C
N/C
N/C
N/C
+5V VCC
IN+
IN-
OUT+
OUT-
ANALOG GND
DIGITAL GND
+5V VCC
CHASSIS GND
MAX A
MAX B
CNTRL2
CNTRL1
DIGITAL GND
MOTOR STEP
POWER CONTROL
MOTOR DIR
5410 MOTOR
20124 ASSEMBLY CONTROLLER
Wiring and Electronic Details
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
53686L002
Control
1
2
3
4
5
6
7
8
9
1
2
3
4
5
6
7
8
9
66280X1 DB15F
10
11
12
13
TB3 Cable
BLACK PCB ASSY. P1 J3
4 A
15 J 7
J8
ORANGE 3 A 15 15 N/C
MOTOR RED J2 SYSTEM ERROR 2 14 14 N/C
DB9F
2 B Feedback
14 D B 1 5 F
YELLOW 1 13 13 DISABLE
1 B Cable 4 IN-
IN+ COMMAND J11 12 12 N/C
3
2 OUT- 11 11 N/C
TB4 SYSTEM FAULT 2 10 10 CURRENT CNTRL
ACTUATOR 1 OUT+ MONITORING
Figure C-2 Wiring Details – Actuator Controller

1 9 9 OPTICAL PWR +5V
CASE 1 TX
Power Cable J10 8 8 DISABLE
2 TX J1
7 7 GND
3 3 CHASSIS GND 6 6 6 GND
4 2 24V RET PWR CTRL 5 5 5 5V OUT
5 1 24V+
25 PIN OPTICAL POWER 4 4 4 N/C
6
RIBBON GND 3 CABLE ASSY. 64162X 3 3 N/C
7
CABLE DIR SIGNAL 2 2 2 DIR SIGNAL
8 TB2 J3
64136X1 Motor STEP SIGNAL 1 1 1 STEP SIGNAL
9
10 A 5 Cable 5 MOTOR GND J6
11 A 4 4 MOTOR B
B 3 3 MOTOR B
66259X POWER SUPPLY
12
13 B 2 2 MOTOR A J2 J2
14 CHGND 1 300’ MAX 1 MOTOR A
0V 4 4 0V
15 J5 J3 12V 3 3 12V
16 DGND
Position
OPTICAL TB1 J4 MOTOR RETURN 2 2 MOTOR RETURN
17 DGND Cable 0V 10 10 0V
ENCODER MOTOR SUPPLY 1 1 MOTOR SUPPLY
18 DGND TX 7 6 VALVE POS + 12V 9 9 12V
19 DGND TX 6 5 VALVE POS - A 8 8 A
20 DGND DGND 5 4 DIGITAL GND A 7 7 A
3 +12V DC B 6 6 B J1 J1
21 +12V 4
22 DGND 3 2 DIGITAL GND B 5 5 B MOTOR GND 6 6 MOTOR GND
23 +12V CHGND 2 1 CHASSIS GND CHASSIS GND 4 4 CHASSIS GND N/C 5 5 N/C
24 DGND CHGND 1 300’ MAX MOTOR GND 3 3 MOTOR GND
ACTUATOR B 4 4 B
25 CHGND 8412E CHASSIS 24V RETURN 2 2 24V RETURN
CASE B 3 3 B MOTOR
CHASSIS + 24VDC IN 1 1 + 24VDC IN A 2 2 A CONTROLLER
TERMINAL A 1 1 A
66281X1 POWER SUPPLY/INTERCONNECT ASSY. FRAME
Wiring and Electronic Details C-3
J5
10 1
1 1
J8
J7
VALVE POS +
1 2 3 4 5 6
VALVE POS –
DIGITAL GND
+12V DC
DIGITAL GND
CHASSIS GND
J4
MOTOR GND
1 2 3 4 5
MOTOR B
MOTOR B
MOTOR A
MOTOR A
J3
PS1
PS3
F3
+
C1
IN–
1 2 3 4
AMOT CONTROLS CORP
IN+
COPYRIGHT © 1997
MADE IN U.S.A.
R1 R2 OUT–
OUT+
J2
ERROR FAULT
K2
K1
Relay Relay
J12
Q1
Q2
PS2
CH GND
1 2 3
24V RET
F2
+24VDC
FLT1
J1
F1
2 1 2 1
Z1
J6
J11
J10
1
J9
PSU/INTERCONNECT BOARD
66281X REV SYSTEM ERROR SYSTEM FAULT
(Dry Contacts) (Dry Contacts)
66287L001 REV 1
TESTED BY DATE
Figure C-3 Power Supply/Interconnect Assembly (66281X1)
C-4 Wiring and Electronic Details
January 27, 1998

Component Identification D-1
Appendix D: Component Identification
See Table D-1 on page D-3 for descriptions.

Figure D-1 Component ID – Actuator Controller (8412)
D-2 Component Identification
Figure D-2 Component ID – Actuator Controller (8412)
January 27, 1998

Table D-1 Component ID – Actuator Controller (8412)

Ref Qty Description
1 1 Equipment box
2 1 Swing out panel assembly
3 1 Power supply assembly
4 1 Stepper driver
5 1 Power supply assembly
6 1 DB15 cable assembly
7 1 DB9 cable assembly
8 14 Screw, M3 X 16, FH
9 1 Stepper driver cable assembly
10 4 Box connector
11 22 Nut, M3
12 23 Lockwasher, M3
13 5 Screw, M3 X 8
14 4 Washer, M3
15 1 Heat sink, stepper driver
(Table refers to Figure D-1 on page D-1 and Figure D-2 on

page D-2.)

Figure D-3 Component ID – Actuator
January 27, 1998

Table D-2 Component ID – Actuator

Ref Qty Description
21 1 Enclosure
22 1 Cover
23 1 Finger washer
24 2 Radial bearing
25 1 Drive gear
26 1 Mounting plate
27 1 Stepper Motor (replace with 11578X101)
28 1 Pinion gear (included in 11578X101 for
replacement)
29 1 Spiral pin
30 8 Screw
31 8 Lockwasher
32 1 Gear, antibacklash
33 1 Optical encoder
34 4 Mounting post
35 4 Cap screw
36 10 Lockwasher
37 2 Stop
38 6 Cap screw
39 1 Bracket
40 1 Terminal PCB
41 6 Screw
42 6 Lockwasher
43 1 Ground (earth) wire
44 1 Ground (earth) screw
45 1 Cable assembly
46 1 O-ring
47 1 Nameplate/wiring details
48 1 Tag (serial/sub assy. no.)
49 2 Drive screw
50 1 Retaining ring
(Table refers to Figure D-3 on page D-4.)
Cartridge Assembly is Shown

Rotated 90˚

Figure D-4 Component ID – Actuator/Valve Assembly (2” Valve Shown)
January 27, 1998

Table D-3 Component ID – Actuator/ Valve Assembly

Ref Qty Description
51 1 Rotary Valve – 2, 5, 12, 25, 30, or 60 Cv
52 1 Rotary Actuator
53 1 Yoke
54 2 Key
55 1 Rigid Coupling
56 4 Capscrew (2” Valve)
56 6 Capscrew (3” Valve)
57 22 Lockwasher (2” Valve)
57 24 Lockwasher (3” Valve)
58 14 Capscrew
59 1 Name Plate (Not Shown)
60 4 Drivescrew (Not Shown)
61 8 Set Screw (Not Shown)
62 4 Capscrew
63 4 Nut
64 4 Washer

Figure D-5 Component ID – 1” Valve Subassembly
January 27, 1998

Table D-4 Component ID – 1” Valve Subassembly

Ref Qty Description
1 1 Body, 1”
2 1 Cartridge Assembly
3 2 Dowel Pin
4 4 O-Ring – Viton
13 1 Cover
14 4 Capscrew
16 2 Position Scale (mounted on yoke, not shown)
17 1 Test Certificate (not shown)
25 1 Body Port
27 1 O-Ring
30 1 Tetraseal
Table D-5 Flow Coefficient (Cv) Codes – 1” Valve

Code Cv Material
F 2 Cv Steel
T 2 Cv Stainless Steel
G 5 Cv Steel
U 5 Cv Stainless Steel
See Table D-6 on page D-11 for descriptions

January 27, 1998


Ref Qty Description
1 1 Body, 2"
2 1 Rotor
3 1 Dowel Pin
4 4 O-ring – Viton
12 1 O-ring
13 1 Cover

Code Cv Material
A 12 Cv Steel
L 12 Cv Stainless Steel
B 25 Cv Steel
M 25 Cv Stainless Steel
C 30 Cv Steel
N 30 Cv Stainless Steel

January 27, 1998


Ref Qty Description
1 1 Body, 3"
2 1 Cartridge Assembly
3 1 Dowel Pin
13 1 Cover
14 8 Capscrew
16 2 Position Scale (not shown)

Code Cv Material
D 60 Cv Steel
P 60 Cv Stainless Steel
January 27, 1998

Mounting Details E-1
Appendix E: Mounting Details
Zinc-plated steel nut, 1/2–13 UNC (2X)

L
C
D
Thread
Note: Not drawn to scale

Zinc-plated steel lockwasher (2X)
Valve C D L T Thread Material Finish

Size (in.) (in.) (in.) (in.)
2” 3.125 ± 0.125 0.5 7.0 1.5 1/2 – 13 UNC Steel Zinc Plate
3” 5.125 ± 0.125 0.5 10.0 1.5 1/2 – 13 UNC Steel Zinc Plate
Figure E-1 1/2'' U-bolts for Mounting 2” and 3” Fuel Valves, Model 4280
E-2 Mounting Details
Note: Not drawn to scale Valve 9/16 D (4X)

Centerline
Valve
Centerline Discharge Inlet
W
Valve A B W
Size (in.) (in.) (in.)
2” 6.0 2.75 3.5625
3” 7.0 3.5 5.5625
Figure E-2 Hole Patterns for Mounting 2” and 3” Fuel Valves with 1/2'' U-bolts
Notes:
1) Not drawn to scale.
2) Dimensions in inches. Valve
Centerline 9/16 D (2X)
Valve
Centerline
Discharge Inlet
2.000
4.000
Figure E-3 Hole Pattern for Mounting 1” Fuel Valve
January 27, 1998

Mounting Details E-3
Zinc-plated steel nut and lockwasher (4X)

Skid Surface
Zinc-plated steel
1/2'' U-bolt (2X)
Figure E-4 Mounting Details for 2” and 3” Fuel Valves (2” Shown)
E-4 Mounting Details
ø0.422 X 1.00 Deep Tap

1/2–13UNC–2B X 0.563 Deep, Skid Surface
Full Thread (2X)
Zinc-plated steel lockwasher (2X)

Zinc-plated steel bolt,
1/2–13UNC–2B (2X)
Figure E-5 Mounting Details for 1” Fuel Valve
January 27, 1998

Spares F-1
Appendix F: Spares
The MTBF for the Rotary Fuel Valve and Controller are given
in Table F-1.
Table F-1 MTBF for Rotary Fuel Valve System
Product MTBF
Model 4280 Rotary Actuated Valve 2 years
Model 8412 Actuator Controller 10 years
The subassembly components and parts which comprise the
Rotary Valve and Controller are classified based on their
probability of failure:
■ Parts Class 1
Failure probable within two years of continuous service.
One set of spare parts should be carried per unit.
■ Parts Class 2
Failure probable within five years of continuous service.
One set of spare parts should be carried at each
installation location.
■ Parts Class 3
Failure not expected within the lifetime of the part.
However, considering criticality and severity of down time
or remoteness of installation, one set of spare parts should
be considered at a central repair parts storage location.
The following tables list the spare subassembly parts
available for the Rotary Valve, Actuator, and Controller, and
recommend a spares strategy (Parts Class) for each.
Table F-2 Rotary Valve Parts
Part Number Description Parts Class

10032X002 Cartridge (2 Cv) (complete) 2
F-2 Spares
Table F-3 Actuator Parts

Complete 4280 Fuel Valve
11578X001 Stepper Motor/Pinion Assy. 1
20116 Drive Gear 1
11561L100 Anti-Backlash Gear (fits to Encoder) 2
11579 Optical Encoder 3
Table F-4 Actuator Controller Parts

Complete 8412 Electronic Controls
66281X1 Power Supply PCB 2
66275X2 LCD Display PCB (Swing-out panel) 2
53686L002 Stepper Motor Driver 2
10435X Fuse and Connector Kit 1
(see Table 3-3 on page 3-4)
January 27, 1998

Product Return Form G-1
Appendix G: Product Return Form
Sales Order No.: ____________________ RMA No.:______________________
Product Serial Numbers:

Actuated Valve Model No. 4280__________________________*
Production Serial Number: . . . . . . . . . . _________________
Individual Serial Number: . . . . . . . . . . . _________________
Actuator Controller Model No. 8412________________________*
* Please specify full model number
Options:
Valve trim size - Cv = _______
Controller Input Voltage: 24 Vdc
Other Notes: ________________________________________________________

__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
__________________________________________________________________
Date that valve entered service________________

Number of hours of operation__________________
G-2 Product Return Form
January 27, 1998

Index–1
A Component Identification
Actuator 1-inch Valve D-8, D-9
Component Identification D-4, D-5 2-inch Valve D-10, D-11
Enclosure 2-4 3-inch Valve D-12, D-13
Mechanical Stops 2-3 Actuator D-4, D-5
Parts F-2 Actuator Controller D-1, D-2, D-3
Position Feedback 2-3 Actuator/Valve Assembly D-6, D-7
Torque 2-3 Configuration 5-7
Actuator Controller Automatic Setup 5-7, 5-9
Component Identification D-1, D-2, D-3 Control Action 5-10
Enclosure 2-4 Figure 5-8
Heat Dissipation 4-5 Hysteresis 5-11
Installation Dimensions B-1 Manual Position 5-7
Installation Requirements 4-5 Manual Setup 5-10
Model Code 3-3 Set Point Fail 5-11
Mounting 4-5 Configuration Sequence 5-8
MTBF F-1 Control Action, Configuration 5-10
Parts F-2 Control Cable 4-6
Power Requirement 4-2 Crack Point 5-2, 5-3
Software Version 5-7 Cv Codes
Status Relays 2-5, 5-14 1-inch Valve D-9
Wiring Details C-2 2-inch Valve D-11
Actuator/Valve Assembly 3-inch Valve D-13
Component Identification D-6, D-7 Cv, Flow Coefficient 2-1
Automatic Operation 5-12
DC Power Failure 5-13
D
DC Power Supply Failure 2-4, 5-13
EEPROM Corruption 5-14
Dead Zone, Flow Characteristic 5-3
Normal Operation 5-12
DIP Switch Settings 5-5
Position Feedback Failure 5-13
Direction of Flow 4-3
Power-Up 5-12
Discharge Venting 4-4
Set Point Failure 5-13
Dowel Pin 2-4, 5-1
Automatic Setup, Configuration 5-7, 5-9
Fully Closed Position 5-7 E
Fully Open Position 5-9 EEPROM Corruption 5-14
LCD Display 5-14
C LED Indication 5-14
Cable Entry Gland 4-4
Electronic Control System Description 2-4
Cables
Enclosure
Control Cable 4-6
Actuator 2-4
Feedback Cable 4-6
Actuator Controller 2-4
Motor Cable 4-7
Encoder Failure 5-13
Position Cable 4-7
Error Relay 2-5, 5-14
Power Cable 4-8
Error Signal 2-4
Cabling Requirements 4-6
ESC Push Button 5-6, 5-7
CLOSE Push Button 5-6, 5-7, 5-9, 5-10, 5-11
Index–2
F Installation Dimensions
Failures 1-inch Valve/Actuator B-2
DC Power Supply 2-4, 5-13 2-inch Valve/Actuator B-3
EEPROM Corruption 5-14 3-inch Valve/Actuator B-4
Encoder 5-13 Actuator Controller B-1
Position Feedback 5-13 Flexitallic Gaskets B-6
Set Point 2-4, 5-13 Weld Neck Flange (2-inch Valve) B-5
Fault Relay 2-5, 5-14 Installation Requirements
Feedback Cable 4-6 Actuator Controller 4-5
Feedback Signal, Output 2-5 Fuel Valve 4-3
Filters 4-4
Flange and Accessories Kit 3-5
L
LCD Display 5-6
Flange Bolts, Torque Requirements 4-3
Flexitallic Gaskets 4-3
Run Mode 5-6
Flow Characteristic, Fuel Valve 2-2, 5-2
Setup Mode 5-6
Dead Zone 5-3
LED Indicators 5-6
Flow Coefficient, Cv 2-1
Flow Crack Point 5-2, 5-3
Position Feedback Failure 5-13
Flow Direction 4-3
Fuel Valve
Flow Characteristic 2-2, 5-2 M
Flow Direction 4-3 Machined Slot 2-4, 5-1
Installation Requirements 4-3 Manual Position, Configuration 5-7
Model Code 3-3 Manual Setup, Configuration 5-10
Mounting 4-3 Fully Closed Position 5-10
Mounting Orientation 4-3 Fully Open Position 5-10
MTBF F-1 Mechanical Description 2-2
Trim Orifices 5-2 Mechanical Stops, Actuator 2-3
Vent Connection 4-4 Setup 5-1
Functional Diagram, Fuel Valve Control 5-12 Model Codes
Fuse and Connector Kit 3-4 Actuator Controller 3-3
Fuel Valve 3-3
G Model Numbers 3-2
Gaskets, Flexitallic 4-3
Motor Cable 4-7
Length vs. AWG 4-7
H Mounting
Heat Dissipation, Actuator Controller 4-5 Actuator Controller 4-5
Hole Patterns, Mounting E-2 Fuel Valve 4-3
Hysteresis, Configuration 5-11 Mounting Details E-1
1-inch Valve E-4
I 2- and 3-inch Valves E-3
Input Requirements 4-2 Hole Patterns E-2
Inspection 3-1 U-bolt E-1, E-3
Mounting Orientation 4-3
MTBF
Actuator Controller F-1
Fuel Valve F-1
January 27, 1998

Index–3
N R
Nameplate Data 3-2 Receiving 3-1
Normal Operation 5-12 Replacement Parts 4-1
Returned Material Authorization 3-1
O Returning Product 3-1
OPEN Push Button 5-6, 5-7, 5-9, 5-10, 5-11 Product Return Form G-1
Operating Modes 5-5 Run Operating Mode 5-5, 5-12
Run 5-5, 5-12 LCD Display 5-6
Setup 5-5, 5-7, 5-8, 5-14 PCB Switch Positions 5-12
Ordering Information 3-4
Output Feedback Signal 2-5 S
SELECT Push Button 5-6, 5-7, 5-9, 5-10, 5-11
P Serial Number 3-2
Parts Class, Spares F-1 Set Point Fail, Configuration 5-11
PCB Switches Set Point Failure 2-4, 5-13
Run Mode 5-5, 5-12 LCD Display 5-13
Setup Mode 5-5 LED Indication 5-13
Piping Connections 4-3 Setup Operating Mode 5-5, 5-7, 5-8, 5-14
Position Cable 4-7 LCD Display 5-6
Position Feedback Failure 5-13 Sequence 5-9
LED Indication 5-13 Setup Sequence 5-8, 5-9
Position Feedback, Actuator 2-3 Setup, Mechanical Stops 5-1
Position Indicator 2-3, 5-3, 5-4 Slot, Machined 2-4, 5-1
Graduations 5-4 Software Version 5-7
Position Signal 2-4 Spares F-1
Resolution 2-4 Actuator Controller Parts F-2
Power Cable 4-8 Actuator Parts F-2
Power Consumption 4-2 Parts Class F-1
Power Failure 2-4, 5-13 Valve Cartridges F-1
Power Requirements 4-2 Specifications 2-5, A-1
Actuator Controller 4-2 Actuator Controller A-2
Power Supply/Interconnect Assembly C-3 Actuator Electrical A-2
Power-Up 5-12 Actuator Mechanical A-1
Precision Dowel Pin 2-4, 5-1 Actuator Performance A-2
Precision Slot, Machined 2-4, 5-1 Environmental–Valve and Actuator A-1
Printed Circuit Board (PCB) 5-5, C-1 Operator Interface A-3
Product Description 2-1 Valve, Mechanical A-3
Electronic Control System 2-4 Weights A-3
Mechanical 2-2 Status Relays 2-5, 5-14
Product Identification 3-2 Storage Requirements 3-1
Product Return Form G-1 Storage Temperature 3-1
Protective Covers 4-1, 4-2 Stroke, Valve 5-2
Push Buttons 5-6 Switches, PCB 5-5
CLOSE 5-6, 5-7, 5-9, 5-10, 5-11 Run Mode 5-5, 5-12
ESC 5-6, 5-7 Setup Mode 5-5
OPEN 5-6, 5-7, 5-9, 5-10, 5-11
SELECT 5-6, 5-7, 5-9, 5-10, 5-11
Index–4
T
Temperature, Storage 3-1
Torque Requirements, Flange Bolts 4-3
Torque, Actuator 2-3
Trim Orifices 5-2
U
U-bolt, Mounting E-1, E-3
User Interfaces 5-6
LCD Display 5-6
LED Indicators 5-6
Push Buttons 5-6
Specifications A-3
V
Valve (1-inch)
Component Identification D-8, D-9
Cv Codes D-9
Valve (2-inch)
Cv Codes D-11
Valve (3-inch)
Cv Codes D-13
Valve Body 2-2
Valve Stroke 5-2
Valve/Actuator Installation Dimensions
1-inch Valve B-2
2-inch Valve B-3
3-inch Valve B-4
Vent Connection 4-4
Vent Line, Orientation 4-4
Venting Discharge 4-4
W
Weld Neck Flange Dimensions (2-inch Valve) B-5
Wiring Details, Actuator Controller C-2
January 27, 1998

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Contents–1

Product Description . . . . . . . . . . . . . . . . . . . . 2-1

Product Information . . . . . . . . . . . . . . . . . . . . 3-1

Cabling Requirements . . . . . . . . . . . . . . . . . . . . . . . 4-6

Configuration and Operation . . . . . . . . . . . . . . . 5-1

January 27, 1998

Installation Dimensions . . . . . . . . . . . . . . . . . . B-1

Wiring and Electronic Details. . . . . . . . . . . . . . . C-1

Component Identification . . . . . . . . . . . . . . . . . D-1

Mounting Details. . . . . . . . . . . . . . . . . . . . . . E-1

Product Return Form . . . . . . . . . . . . . . . . . . . G-1

Figure 3-1 Rotary Fuel Valve Nameplate . . . . . . . . . . . . . . 3-2

Figure 4-1 Control Box Mounting . . . . . . . . . . . . . . . . . . 4-5

Figure 5-1 Precision Dowel Pin and Machined Slot . . . . . . . . . 5-1

Figure B-1 Installation Dimensions – Actuator Controller . . . . . . B-1

Figure C-1 Printed Circuit Board . . . . . . . . . . . . . . . . . . . C-1

Figure D-1 Component ID – Actuator Controller (8412) . . . . . . . D-1

January 27, 1998

Figure D-5 Component ID – 1” Valve Subassembly . . . . . . . . . D-8

Figure E-1 1/2'' U-bolts for Mounting 2” and 3” Fuel Valves,

Table 3-1 Model Numbers . . . . . . . . . . . . . . . . . . . . . 3-2

Table 4-1 Flange Bolt Torque Values . . . . . . . . . . . . . . . . 4-4

Table 5-1 Valve Position for each Graduation . . . . . . . . . . . 5-4

Table A-1 Actuator Specifications . . . . . . . . . . . . . . . . . A-1

Table D-1 Component ID – Actuator Controller (8412) . . . . . . . D-3

Table F-1 MTBF for Rotary Fuel Valve System . . . . . . . . . . F-1

January 27, 1998

Chapter 1: Document Introduction

This document is intended to provide all the information

Document The contents of this document are described below, with

Conventions The following conventions are used throughout this

occurrence in the document and may be defined at other

Note: Notes contain important information which needs to be

Caution: Cautions contain instructions which, if not followed, could

Warning! Warnings contain instructions which, if not followed,

■ Revision Control — The document revision level follows

January 27, 1998

Chapter 2: Product Description

The Rotary Fuel Valve system precisely controls the flow of

The fuel flow characteristics of the valves are approximately

Mechanical Fuel Valve Model 4280

January 27, 1998

The positions of the mechanical stops in the actuator are

Electronic Actuator Controller Model 8412

January 27, 1998

Nonisolated A 4-20 mA position feedback signal is provided by the

Note: This position feedback loop is powered by the controller (24

Controller A system FAULT relay is provided to indicate a complete

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January 27, 1998

Chapter 3: Product Information

Receiving Upon receipt, the equipment should be carefully inspected for

Inspection Carefully unpack the equipment taking care to save the

Storage If the actuator will not be installed immediately, it should be

Returned In the event the valve or controller requires service, obtain a

Nameplate A nameplate, as shown in Figure 3-1, which includes a model

Figure 3-1 Rotary Fuel Valve Nameplate

Note: When ordering parts or requesting information or service

January 27, 1998

Fuel Valve Model Example:

Basic Model No. Special

L 2", ANSI Class 600, Stainless Steel, linear trim, 12 Cv

Basic Model No. Special Requirements

Table 3-2 provides ordering information and a part number for