Operations

Manual

HFG2.0
Gas Fuel Metering Valve
SD-6009-02
 HFG2.0

PREFACE
This manual provides installation, maintenance, and operating instructions for the
HFG2.0 Gas Fuel Metering Valve.
Every attempt has been made to provide sufficient information in this
manual for the proper operation and preventive maintenance of the valve.
It is recommended that the user read this manual in its entirety.
Operating the HFG2.0 Gas Fuel Metering Valve in accordance with instructions
herein ensures long term and reliable operation.

If additional information is required, please contact:

Marketing Department
Precision Engine Controls Corporation
11661 Sorrento Valley Road
San Diego, California 92121
USA
(858) 792-3217 x (800) 200-4404
fax: (858)792-3200
e-mail: peccntl@precisioneng.com

© 2000 PRECISION ENGINE CONTROLS CORPORATION. ALL RIGHTS RESERVED

 HFG2.0

Table of Contents
1. INTRODUCTION............................................................................................................................. 1-1
1.1 Application .................................................................................................................................... 1-1
1.2 Electric Actuator ........................................................................................................................... 1-2
1.3 Valve Flow Body Assembly ......................................................................................................... 1-2
1.4 Identification Plate ........................................................................................................................ 1-4
2. FUNCTIONAL DESCRIPTION AND OPERATION ...................................................................... 2-1
2.1 System Description ...................................................................................................................... 2-1
2.2 Electronic Description .................................................................................................................. 2-1
2.3 Mechanical Description................................................................................................................ 2-6
2.4 Basic Operation............................................................................................................................ 2-6
2.5 FAULT Alarm................................................................................................................................ 2-7
2.6 OVERTEMP Alarm ...................................................................................................................... 2-8
3. INSTALLATION............................................................................................................................... 3-1
3.1 Inspection ..................................................................................................................................... 3-1
3.2 Environmental Considerations .................................................................................................... 3-1
3.3 Mechanical Installation................................................................................................................. 3-1
3.4 Electrical Installation..................................................................................................................... 3-3
4. TROUBLESHOOTING.................................................................................................................... 4-1
5. MAINTENANCE .............................................................................................................................. 5-1
5.1 Cleaning........................................................................................................................................ 5-1
6. DECOMMISSIONING AND DISPOSAL ........................................................................................ 6-3
7. GENERAL SPECIFICATIONS ....................................................................................................... 7-1
8. GLOSSARY..................................................................................................................................... 8-1

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HFG2.0

List of Figures

Figure 1-1: HFG2.0.............................................................................................................1-1

Figure 1-2: HFG2.0 Cutaway View....................................................................................1-4
Figure 1-3: Typical Identification Plate...............................................................................1-4
Figure 2-2: Typical Power Connection ..............................................................................2-3
Figure 2-3: Typical Discrete Command Connection ........................................................2-4
Figure 2-4: Typical Analog Input Connection....................................................................2-4
Figure 2-5: Typical Analog Output Connection.................................................................2-4
Figure 2-6: Typical Fault Alarm Connection......................................................................2-5
Figure 3-1: HFG2.0 Envelope............................................................................................3-2
Figure 3-2: HFG2.0 Wiring Diagram..................................................................................3-7

List of Tables

Table 3-1: Power Harness Recommended Wire Size .....................................................3-4

Table 3-2: Signal Harness Recommended Wire Size .....................................................3-4
Table 3-3: HFG2.0 Power Harness Wire List ...................................................................3-6
Table 3-4: HFG2.0 Digital Harness Wire List....................................................................3-8
Table 3-5: Power Supply Requirements ...........................................................................3-8
Table 4-1: HFG2.0 Initial Installation Troubleshooting Chart ...........................................4-2
Table 4-2: HFG2.0 In-Service Troubleshooting Chart......................................................4-3
Table 4-3 HFG2.0 Electrical Hook-Up Continuity Troubleshooting Chart......................4-3

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 HFG2.0

1. INTRODUCTION
This publication covers operation, installation and maintenance instructions for
Precision Engine Controls Corporation HFG2.0 Gas Fuel Metering Valve. The
HFG2.0 is shown in Figures 1-1 and 1-2.
Careful attention to all sections in this manual will increase expected valve life,
and provide years of service.

1.1 Application
The HFG2.0 Gas Fuel Metering Valve is designed to meet industrial gas turbine
fuel control requirements for high temperature hazardous locations (explosion
proof). The HFG2.0 controls fuel flow for industrial gas turbines up to 30 MW.

Figure 1-1: HFG2.0

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HFG2.0

1.2 Electric Actuator

The HFG2.0 incorporates a fully self contained, explosion proof, brushless DC

motor driven electric actuator. The actuator contains a drive mechanism, resolver
and motor control electronics (MCE).

A brushless DC motor and ball screw assembly provides the primary drive
mechanism. A non-contacting resolver provides position feedback and motor
commutation information.

The MCE integrates with a user-provided control system that is typically a

programmable logic controller (PLC). The MCE accepts analog fuel demand, and
discrete RUN and RESET command inputs. The MCE provides optically isolated
position feedback and motor current analog outputs. The MCE provides discrete,
optically isolated FAULT and OVERTEMP alarm outputs.

Note: The MCE analog and discrete interfaces are electrically isolated.
The MCE serial interface is NOT electrically isolated.

The actuator electrical interface is provided via leads ninety inches in length
emanating from two ¾ “ NPT conduit unions. The power and signal harnesses
are provided in separate conduit unions.

Four power leads emanate from the power harness. These leads provide primary
and auxiliary 120 VDC power.

Seventeen leads emanate from the signal harness. These leads provide HFG2.0
analog, discrete and serial interface connections.

For more information refer to the ACT2000 All-Electric Actuator Operations

Manual.

1.3 Valve Flow Body Assembly

The electric actuator and the valve flow body assembly are mechanically
connected together via eight bolts and threaded poppet assembly.
See Figure 1-2.

The valve flow body assembly (main pressure vessel) is made up of three valve
body sub-assemblies (upper, center, and lower). These three valve body sub-
assemblies are bolted together via eight, ½” diameter, high strength, steel bolts.
Two Viton o-rings and redundant pressure energized dynamic seals provide the
gas tight boundary. The lower valve body assembly is provided with a ¼” NPT
fitting to drain coalescent material, if necessary.

Fuel metering is accomplish via a pressure balanced, poppet assembly and fixed
orifice plates. Fuel flows in the annulus between the poppets and fixed orifices. In
the closed position, the pressure energized soft seats, along with metal-to-metal

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 HFG2.0

hard seats, provide a leak tight seal. A fail-safe spring is connected between
upper poppet and upper valve body to assure closure in case of power failure.

Electric Actuator

Power Harness

Signal Harness
Poppet Assembly

Dynamic Seal
Return Spring Soft Seat

Orifice
O-ring
Valve Flow Body

Contamination
D fl t
Orifice
Soft Seat

O-ring

Drain Port

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HFG2.0

Figure 1-2: HFG2.0 Cutaway View

1.4 Identification Plate

A product identification plate is attached to the valve

housing assembly. Figure 1-3 shows a typical
identification plate.

The identification plate lists model designation,

product part number, revision and unit serial number.
Hazardous area operation and electrical wiring
interface information is also provided.

Figure 1-3: Typical Identification Plate

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2. FUNCTIONAL DESCRIPTION AND OPERATION

This section describes system theory and functions employed in the HFG2.0 Gas
Fuel Metering Valve.

2.1 System Description

The HFG2.0 is a closed loop servo system containing Motor Control Electronics
(MCE), a brushless DC motor driven ball screw actuator and valve flow body
assembly. The valve closes its own control loop on an internally generated
position feedback. Thus, the valve continuously modulates its position and
provides precise fuel metering.

The HFG2.0 requires only 120VDC power, a 4-20 mA fuel Demand, and a
discrete RUN command to achieve basic operational capability. The HFG2.0
provides fuel demand and motor current feedback via integral 4-20 mA circuits.
Complete fault diagnostics are available via the supplied serial port. Information
regarding these functions is provided in later sections of this manual.

Once 120VDC power and RUN command are supplied, the valve will begin
tracking fuel demand. The valve closed position is 4 mA and fully open position is
20 mA. The valve will not track fuel demand between 4.0 and 4.1 mA and will
remain closed. Once fuel demand is greater than 4.1 mA, the valve will provide
flow that is linearly proportional to fuel demand for the calibrated conditions.

2.2 Electronic Description

The HFG2.0 electric actuator incorporates digital motor control electronics. The
motor control electronics (MCE) contain analog to digital converters, a digital
signal processor (DSP), application specific integrated circuit (ASIC) and power
supplies. The electronic system block diagram is shown in Figure 2-1.

The MCE provide interface for the user’s engine control system and power
supply. The MCE incorporates analog and discrete inputs and outputs, as well
as, a serial interface. The MCE provides signal conditioning for all external analog
and discrete I/O, as well as, internal resolver and thermister inputs.

The MCE internally interfaces with the brushless DC motor, resolver and
thermisters. The MCE performs all necessary commutation, control and health
monitoring for the HFG2.0.

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 HFG2.0

DRIVER ASSY
120V ACTUATOR RED
REVERSE
POWER + WHITE/RED POLARITY
(80 - 160 VDC) PROTECTION
GREEN POWER BRUSHLESS
WHITE/GREEN
- ELECTRONICS DC MOTOR
POWER
INTERFACE

DEMAND BROWN
INPUT OPTICAL ISOLATION
WHITE/BROWN TERMINATION
DEMAND RTN

YELLOW
POSITION RESOLVER
YELLOW/WHITE
POSITION RTN 4-20mA
MTR CURRENT BLUE OUTPUT

MTR CURRENT RTN WHITE/BLUE

CONTROL
ELECTRONICS
OPTICAL
VIOLET ISOLATION
RUN
BALL SCREW
WHITE/VIOLET
RUN RTN AND
RESET GRAY SHAFT
WHITE/GRAY
RESET RTN
FAULT ALARM ORANGE

FAULT RTN WHITE/ORANGE

OVERTEMP ALARM BLACK

OVERTEMP RTN WHITE/BLACK

SERIAL TX OUT WHT/ORN/BLU

SERIAL RX IN WHT/ORN/YEL RS-232 DRIVER
SERIAL RTN WHT/ORN/GRN

CONTROL
INTERFACE
DIGITAL ASSY

HFG2.0 ACTUATOR

Figure 2-1: HFG2.0 Electronics System Block Diagram

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 HFG2.0

2.2.1 Power
The HFG2.0 operates on nominal 120 VDC, user-provided input voltage via the
four-wire power harness. Refer to Figure 2-2 for typical connection
Primary Power Wires:
x +120 VDC is connected to the RED wire.
x The 120 VDC return wire is GREEN.
Redundant power wires:
x +120 VDC is connected to the WHITE/RED wire.
x 120 VDC return wire is WHITE/GREEN.

HFG 2.0 120V INPUT

BATTERY/POWER SUPPLY PWR [RED]
PWR AUX [WHT/RED]
120VDC FUSE REVERSE VOLTAGE PROTECTION
PWR RTN AUX [WHT/GRN]
PWR RTN [GRN]

Figure 2-2: Typical Power Connection

WARNING:
Shock Hazard – Both the 120 VDC power and auxiliary wires should be
connected. If only the primary power wires are connected, the 120 VDC
auxiliary power wires are electrically “hot” and must be insulated on the
ends.

Note: If a 120 VDC power supply is used, it must have at least 12,000 uF
internal capacitance. See Power Supply Requirements (Table 3-5).

2.2.2 Discrete Commands

The HFG2.0 accepts two discrete, two-wire external commands: RUN and
RESET. The commands are 24 VDC ON (High) and 0 VDC OFF (Low). Refer to
Figure 2-3 for typical connection. Refer to Section 7 for load specification values.

CONTROLLER DISCRETE OUTPUT HFG2.0 DISCRETE INPUT

RUN [VIO]
RESET [GRY]
24Vdc

RUN RTN [WHT/VIO]

RESET RTN [WHT/GRY]

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HFG2.0

CONTROLLER DISCRETE OUTPUT

HFG2.0 DISCRETE INPUT
RUN [VIO]
RESET [GRY]

RUN RTN [WHT/VIO]

RESET RTN [WHTGRY]

Figure 2-3: Typical Discrete Command Connection

Run Command
The RUN command is a user provided discrete input to the HFG2.0 which allows
the valve to track fuel demand. RUN command loss (or removal) will cause the
valve to close. The +24 VDC signal shall be provided on the VIOLET wire. The
signal return shall be provided on the WHITE/VIOLET wire.

Reset Command
The RESET command is a user provided discrete input to the HFG2.0, which
causes the valve to close, go through initial homing sequence and reset all
internal position indicators. RUN and fuel demand inputs are ignored during the
RESET command. The +24VDC signal shall be provided on the GRAY wire. The
signal return shall be provided on the WHITE/GRAY wire.

2.2.3 Analog Inputs/Outputs

The HFG2.0 receives analog fuel demand from an external, user-provided
controller and provides analog valve position and motor current feedback. Refer
to Figures 2-4 and 2-5 for typical connection. Refer to Section 7 for load
specifications values.

CONTROLLER 4-20mA OUTPUT HFG2.0 4-20mA INPUT

DEMAND [BRN]
+ +
200:
- DEMAND RTN [WHT/BRN] -

Figure 2-4: Typical Analog Input Connection

CONTROLLER 4-20mA INPUT HDG 2.0 4-20mA OUTPUT

POSITION [YEL]
+ MTR CURRENT [BLU] +
<500:
- POSITION RTN [WHT/YEL] -
MTR CURRENT RTN [WHT/BLU]

Figure 2-5: Typical Analog Output Connection

Fuel Demand
The fuel demand is a user provided analog input that causes the valve to provide
fuel flow per a predetermined schedule. The valve will remain fully closed with
fuel demand less than 4.1 mA. The valve will incrementally meter fuel at
demands between 4.1 mA and 20 mA. Fuel demand is limited to 20 mA.

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 HFG2.0

The fuel demand shall be provided on the BROWN wire. The fuel demand return
shall be provided on the WHITE/BROWN wire. The fuel demand internal
impedance is 200 ohms. The fuel demand requires a sourcing current.

Position Feedback
The HFG2.0 provides valve analog position feedback to the user. This internally
generated feedback signal is proportional to fuel flow.
The valve position feedback is provided on the YELLOW wire. The valve position
feedback return is provided on the WHITE/YELLOW wire. The expected external
impedance is 250 ohms. The maximum external impedance is 500 Ohms.

Motor Current Feedback

The HFG2.0 provides motor current feedback to the user. This internally
generated feedback signal is proportional to actuator load. 4mA represents no
load on the actuator. 20mA is the maximum load.
The motor current feedback is provided on the BLUE wire. The motor current
feedback return is provided on the WHITE/BLUE wire. The expected external
impedance is 250 ohms. The maximum external impedance is 500 Ohms

2.2.4 Fault Alarms

The discrete alarm outputs are solid state switches that are normally closed. The
user controller provides 24 VDC to complete the circuit. If a FAULT or
OVERTEMP alarm has occurred, the switch opens thereby communicating an
alarm to the user’s controller. Refer to Figure 2-6 for typical connection. Refer to
Section 7 for load specifications values.

CONTROLLER DISCRETE INPUT

HFG2.0 DISCRETE OUTPUT

FAULT ALARM [ORN]
OVERTEMP ALARM [BLK]

FAULT RTN [WHT/ORN]

OVERTEMP ALARM RTN [WHT/BLK]

HFG2.0 DISCRETE OUTPUT

CONTROLLER DISCRETE INPUT
FAULT RTN [WHT/ORN]
OVERTEMP ALARM RTN [WHT/BLK]

FAULT ALARM [ORN]

OVERTEMP ALARM [BLK]

Figure 2-6: Typical Fault Alarm Connection

The FAULT alarm is provided on the ORANGE wire. The FAULT alarm return is
provided on the WHITE/ORANGE wire.
The OVERTEMP alarm is provide on the BLACK wire. The OVERTEMP alarm
return is provided on the WHITE/BLACK wire.

WARNING:

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HFG2.0

Property Damage Hazard – Connection of 24VDC power across the discrete

output will cause electrical failure of the output. Series resistance should
be added to the 24VDC output from the controller.

2.2.5 RS232 Communications

RS232 serial communications is achieved with user-provided input to the Serial
Rx In, Serial Tx Out and Serial Rtn wires.
x The Serial RX In wire is WHITE/ORANGE/YELLOW.
x The Serial Tx Out wire is WHITE/ORANGE/BLUE.
x The Serial Rtn wire is WHITE/ORANGE/GREEN.
The RS232 wires are used to communicate the HFG2.0 set-up parameters and
fault diagnostics. Contact Precision Engine Controls Corporation for fault
diagnostic software.

2.3 Mechanical Description

Gas (or liquid) fuel enters the valve flow body assembly INLET port. See Figure
1-2. The fuel flow is evenly split via a contamination deflector and pressure
balanced orifice assembly.
The pressure balanced orifice assembly contains a set of poppets and control
orifices. The orifices contain hard and pressure energized soft seats. In the
closed position, poppets are sealed leak tight via these hard and soft seats.

WARNING:
Explosion Hazard – The soft seats are unidirectional and will leak if the
OUTLET is more than 50 psig greater than INLET. PECC recommends that
the INLET port pressure always be greater than or equal to the OUTLET
port pressure.

As the valve actuator retracts, the poppet assembly begins to expose fuel to the
two orifices. The fuel flows through the orifice annulus and recombines in the
OUTLET port chamber. The fuel exits through the OUTLET port.
A pre-loaded, fail-safe spring is located between valve housing and poppet
assembly. The spring load increases as the valve is opened. Should a power
failure occur, the spring causes the poppets to return to the soft seats, thereby
closing the valve.

2.4 Basic Operation

2.4.1 Power-Up
When 120 VDC is applied, the actuator will retrieve all necessary operating
parameters from non-volatile memory and perform an internal health check.

WARNING:

2-6
 HFG2.0

Property Damage Hazard – Always remove RUN command during power

up and communication modes. If a RUN command is given during
program download, the valve will not respond until download is complete.

Once the program is complete with a health check, it waits for RUN command.
Upon receipt of RUN command, the HFG2.0 slowly increases motor current to
seat poppet assembly. When the pre-determined motor current limit is reached,
the HFG2.0 defines this position as closed. Fuel demand is internally calculated
with respect to the closed position.
As the HFG2.0 actuator moves, fuel is metered through the orifices. At maximum
demand, 20 mA, the actuator has retracted up to one inch. The actuator will track
as long as fuel demand greater than 4.1 mA and RUN is present.

Note: If RUN command is lost, the HFG2.0 will close.

2.4.2 Health Monitoring

If any of the health parameters are out of the normal operating range, the HFG2.0
outputs a discrete FAULT alarm. If the motor or electronics temperature are
above the normal operation range, the HFG2.0 outputs a separate OVERTEMP
alarm. If any of these faults have occurred, the user should shut down the
HFG2.0 to investigate the failure cause
If the HFG2.0 is operational, a fault file can be uploaded via the RS232 interface.
The fault file will provide fault information and possible cause. Contact Precision
Engine Controls Corporation for fault diagnostic software.

2.4.3 Automatic Shutdown

The HFG2.0 has a self-protective shutdown feature.
x If any two motor winding temperatures exceed 135q C for 10 seconds, the
valve will shut down.
x If the electronics temperature exceeds 115q C for 10 seconds, the valve will
shut down.
x Valve position feed back and motor current will be set to 0 mA when the valve
shuts down.

WARNING:
Injury and Property Damage Hazard – If the motor windings exceed 135q C
or the electronics exceed 115q C, the MCE will shut down power to the
motor and the HFG2.0 will close.

2.5 FAULT Alarm

The FAULT alarm is a discrete output from the HFG2.0. The FAULT circuit is
CLOSED in the normal operating condition.

2-7
HFG2.0

Upon power-up, the FAULT circuit closes. During normal operation, the HFG2.0
monitors the system health. When the HFG2.0 detects a system fault, the FAULT
circuit is opened. The user-provided controller should detect the open circuit.
Some FAULT causes are:
x MCE over-current
x Tracking error
x RDC failure
x Input voltage out of range
Should a FAULT occur, the user should take proper action to access the failure
cause. Toggling the RESET command will clear the FAULT alarm, but it does
not clear the fault file. The valve will close after the RESET command is issued.

2.6 OVERTEMP Alarm

The OVERTEMP alarm is a discrete output from the HFG2.0. The OVERTEMP
circuit is CLOSED in the normal operating condition.
Upon power-up, the OVERTEMP circuit closes.
During normal operation, the HFG2.0 monitors the electronics and motor winding
temperatures. If HFG2.0 detects the motor or electronics temperature above
normal range, the OVERTEMP circuit is opened. The user-provided controller
should detect the open circuit.
An OVERTEMP Alarm will be indicated if the motor winding temperature is 130°
or higher for 10 (ten) seconds or the electronics temperature is 110°C or higher
for 10(ten) seconds.
Should an OVERTEMP alarm occur, the user should shut down the HFG.
Removing 120 VDC power shuts down the HFG. Toggling the RESET command
will clear the FAULT Alarm, but it does not clear the fault file.

Note: The MCE will shut down the valve if the temperature limits are
exceeded. The OVERTEMP alarm will occur approximately 5qC
prior to exceeding temperature limits.

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 HFG2.0

3. INSTALLATION
The purpose of this section is to aid users in the installation, placement, and
environmental considerations to be observed for the HFG2.0 and associated
equipment.

3.1 Inspection
The HFG2.0 should be checked for damage immediately after unpacking, paying
particular attention to the external lead wires.

Note: Retain the valve’s original shipping container. In the event of future
transportation requirements, this container will minimize damage
during shipment.

3.2 Environmental Considerations

The HFG2.0 will operate satisfactorily with ambient air temperature of –40 qC
(-40 qF) to +93 qC (+200 qF). The HFG2.0 is designed as an explosion-proof
assembly. The HFG2.0 enclosure is Canadian Standards Association (CSA)
Type 3 and European IP65 weatherproof. Care should be taken to ensure no
direct exposure to high velocity fluids and solvents.

WARNING:

Burn Hazard – Do not touch valve during high temperature gas operation.
Valve surface temperatures can be up to 135q C (275q F). Touching valve
body at this temperature could result in serious burn injury.

3.3 Mechanical Installation

This section describes proper HFG2.0 installation. Care should be exercised to
ensure compliance with the factory recommendations.

3.3.1 Space Requirements

Figure 3-1 shows external dimensions and mounting provisions for the HFG2.0.

3.3.2 Mounting Considerations

The HFG2.0 may be directly mounted to a gas turbine engine skid using brackets
provided by the engine manufacturer. The HFG2.0 may be mounted in any
orientation (UP, DOWN, SIDEWAYS).
Valve life is maximized if mounted as shown in Figure 3-1. Furthermore, the drain
hole is most effective when mounted in this orientation

Note: Ensure adequate clearance is provided to the OUTLET port to

facilitate cleaning.

3-1
HFG2.0

Figure 3-1: HFG2.0 Envelope

3.3.3 Pipe Connections

The HFG2.0 standard pipe connection is per SAE J518, -32 (2 inch), code 61.
The valve bodies contain locking helical inserts. Please contact Precision Engine
Controls for other connection options.
Precision Engine Controls recommends the following bolts and torque values:
x Flange Bolts- SAE Grade 5 or better. Torque: 650 – 800 in-lb.

WARNING:
Fuel Leakage Hazard – Do not over-torque fittings. Over-torque may result
in stripped threads and / or helical insert damage.

3.3.4 Fuel Filtering

For efficient valve operation, the fuel should be adequately filtered through a 40-
micron absolute filter. This should extend time between routine maintenance. The
fuel filter should be located as close as possible to the valve INLET.

3-2
 HFG2.0

3.3.5 Lifting Considerations

The aluminum body HFG2.0 weighs approximately 100 lbs. The stainless steel
body HFG2.0 weighs approximately 190 lbs. Therefore, it is highly recommended
to use the 0.375 inch diameter clevis to lift the valve.

Note: The clevis has a Factor of Safety (FOS) exceeding the FOS
requirement of 3 based on component yield strength per ASME
B30.20-1999.

WARNING:
Lifting Hazard – Do not attempt to hand lift valve. Serious back injury may
result. Use appropriate lifting equipment.

3.4 Electrical Installation

The HFG2.0 is suitable for use in hazardous locations. See nameplate
for certifications. Care should be taken to ensure compliance with the factory
recommendations. Wiring must be in accordance with local requirements.

WARNING:
Explosion Hazard – Do not connect or disconnect while circuit is live. For
US Group B hazardous locations, an explosion proof seal must be placed
within 18 inches.
Injury Hazard – Keep fingers away from poppets and orifices during
electrical installation.
Property Damage Hazard – Disconnect all HFG connections prior to
welding.

3.4.1 Wiring Specifications and Requirements

This section describes the recommended power and control harness wiring to the
HFG2.0. The HFG2.0 can operate up to 500 feet from the power source. Please
consult Precision Engine Controls Corporation if there are any questions.
Power Harness Recommended Wiring
Under normal operation and load, the HFG2.0 requires less than one (1) amp
input current.
Under transient operation the HFG2.0 may require up to 20 amps of current and
source up to 5 amps of current.
The recommended wiring is a two-conductor, shielded cable containing twisted-
pair wires with individual shields. Use a wire size large enough to accommodate
the installation and provide maximum one (1) ohm loop resistance. See Table 3-1
(below) for recommended wire sizes.

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HFG2.0

Distance to User Power Wire Size (Minimum)

Up to 500 ft AWG 10 stranded
Over 500 ft Consult Factory

Table 3-1: Power Harness Recommended Wire Size

Note: Use a separate conduit for the power wiring. This will prevent noise
pickup and transmission from ancillary equipment, which could
cause instability in the valve.
WARNING:
Shock Hazard – Both the 120 VDC power and auxiliary wires should be
connected. If only the primary power wires are connected, the 120 VDC
auxiliary power wires are electrically “hot” and must be insulated on the
ends.

Signal Harness Recommended Wiring

The signal harness contains both analog and digital inputs and outputs. The
analog inputs and outputs are 4mA to 20mA and are electrically isolated up to
500 VAC from the enclosure, 120VDC power, digital I/O, and serial interface. The
analog interfaces are not isolated from each other.

Note: For proper operation of the valve, the voltage between the control
inputs and the negative terminal of the power supply should be
below 200 VDC.

The discrete inputs and outputs are 24 VDC and are electrically isolated up to
500 VAC.
The recommended wiring is a fourteen-conductor shielded cable containing
twisted-pair wires with individual shields. Use a wire size large enough to
accommodate the installation and provide a maximum fifty (50) ohm loop
resistance. See Table 3-2 for recommended wire sizes.

Distance to User Controller Wire Size (Minimum)

Up to 1000 ft AWG 18 stranded
Over 1000 ft Consult Factory

Table 3-2: Signal Harness Recommended Wire Size

Shielded Wiring
All shielded cable must be a twisted conductor pair with either a foil or braided
shield. All signal lines should be shielded to prevent picking up stray signals.
Connect shields per Figure 3-2. Wire exposed beyond the shield should be as
short as possible.

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 HFG2.0

CE Mark Wiring

WARNING:
Property Damage Hazard – This valve is 89/339/EEC EMC Directive
compliant (CE mark) using watertight, flexible conduit (plastic over steel)
and Belden 8719 shielded, twisted pair audio, broadcast and
instrumentation cable. Use of other conduit or wire invalidates EMC
Directive compliance.
Property Damage Hazard – Do Not connect 24VDC power without current
limiting (25 mA) across digital or analog outputs.

Serial Wiring
The serial inputs are not electrically isolated. Isolation must be provided when
connecting to a computer.

WARNING:
Property Damage Hazard – Serial inputs are not electrically isolated. Failure
to properly isolate the user serial interface could result in property
(computer) damage. Use separate conduits for power and signal wiring.
Close proximity to power lines may cause signal interference.
Shock Hazard – The serial inputs are not electrically isolated. If the 120 VDC
power input is floating (not grounded), the Serial Input connections may
have up to120 VDC present.
Property Damage Hazard – DO NOT connect 24VDC power to any of the
serial interface connections.

Note: Serial connection limited to 50 ft for local interface only with laptop PC.

3.4.2 Wire Lists

This section will provide HFG2.0 wire hook-up information.

Power Harness Electrical Hook-Up

Table 3-3 shows the factory wiring for the HFG2.0 power

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HFG2.0

Wire Color Function AWG

RED Power 14
WHITE/RED Power (AUX) 14
GREEN Power Return 14
WHITE/GREEN Power Return (AUX) 14
Table 3-3: HFG2.0 Power Harness Wire List

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 HFG2.0

Power Harness Electrical Hook-Up

POWER SUPPLY HFG 2.0

+120V PWR (RED)
PWR [AUX] (WHT/RED)
-120V Return PWR RTN (GRN)
PWR RTN [AUX] (WHT/GRN)
Power Gnd Shield Shield No Connection

Digital Harness Electrical Hook-Up

DEMAND (BRN)
Demand
DEMAND RTN (WHT/BRN)
Return
Shield No Connection
Shield Gnd
Run RUN (VIO)
Return RUN RTN (WHT/VIO)
Shield Gnd Shield No Connection

Reset RESET (GRY)

Return RESET RTN (WHT/GRY)
Shield Gnd Shield No Connection

Motor Current MTR CURRENT (BLU)

Motor Current RTN MTR CURRENT RTN(WHT/BLU)
Shield Gnd Shield No Connection

Position POSITION (YEL)

Position RTN POSITION RTN(WHT/YEL)
Shield Gnd Shield No Connection

Fault Alarm FAULT ALARM (ORN)

Fault Alarm FAULT RTN (WHT ORN)
Shield Gnd Shield No Connection

Over Temp Alarm OVERTEMP ALARM (BLK)

Over Temp Alarm OVERTEMP RTN (WHT/BLK)
Shield Gnd Shield No Connection
Shield Gnd Shield No Connection

Serial RX in SERIAL TX OUT (WHT/ORN/BLU)

Serial TX out SERIAL RX IN (WHT/ORN/YEL)
Serial RTN SERIAL RTN (WHT/ORN/GRN)
Shield Gnd Shield No Connection
ENGINE CONTROLLER HFG

Figure 3-2: HFG2.0 Wiring Diagram

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HFG2.0

Table 3-4 shows the factory wiring and reference signals for the HFG2.0 signal
harness.

Note: The serial wiring is segregated from the other wires.

Wire Color Function AWG Signal

WHITE/ORANGE/YELLOW Serial/RX In 20 r 12 V
WHITE/ORANGE/BLUE Serial/TX Out 20 r 12 V
WHITE/ORANGE/GREEN Serial Return 20 0V
BLACK OVER TEMP Alarm 20 0 / 24 V
WHITE/BLACK OVER TEMP Alarm Return 20 0V
ORANGE FAULT Alarm 20 0 / 24 V
WHITE/ORANGE FAULT Alarm Return 20 0V
VIOLET RUN Command 20 0 / 24 V
WHITE/VIOLET RUN Command Return 20 0V
GRAY RESET Command 20 0 / 24 V
WHITE/GRAY RESET Command Return 20 0V
BROWN Demand 20 4 – 20mA
WHITE/BROWN Demand Return 20 0V
YELLOW Position Feedback 20 4 – 20mA
WHITE/YELLOW Position Feedback Return 20 0V
BLUE Motor Current 20 4 – 20mA
WHITE/BLUE Motor Current Return 20 0V
Table 3-4: HFG2.0 Digital Harness Wire List

Power Supply Requirements

A battery power system is recommended. Table 3-5 lists the power supply
requirements.

Note: The serial return is connected to the 120 V input return.

Voltage: 120VDC nominal
80VDC minimum
160VDC maximum
Max Ripple: 4 VAC RMS or 12VAC p-p
Max Current: 20 A
Typical Continuous <1 Amp
Current
Typical Transient Current: +20 A <60 ms
+10A <120ms
-5A <100 ms
*Output Capacitance: 12,000 uF
*The output capacitance applies for non-battery power systems and assumes full stroke step changes in HFG2.0
position.

Table 3-5: Power Supply Requirements

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 HFG2.0

4. TROUBLESHOOTING
The information contained in this section is intended to aid maintenance
technicians in troubleshooting and isolating causes of malfunctions in the
HFG2.0. Most electrical fault isolation of the valve can be accomplished by using
an external oscilloscope and digital voltmeter (DVM).
The HFG2.0 is comprised of highly reliable components and should not develop
service problems under normal operating conditions. However, over a period of
time and service, failures may develop. Personnel responsible for fault analysis
should be thoroughly acquainted with physical and electrical configurations,
Theory of Operation (Section 2), and Installation (Section 3).
Resolve problems noted during operation or maintenance as soon as possible.
The causes of many problems can be traced through the information contained in
the block diagrams shown in Section 2.

WARNING:
Injury and Property Damage – Continuing to operate the valve in a
malfunctioning condition is hazardous to personnel and can cause
property damage or serious injury.

Table 4-1 lists some common failures that can occur upon initial valve installation.
Table 4-2 lists some common failures that can occur after initial installation.
In addition, the HFG2.0 has some on-board troubleshooting capability. To
pinpoint failure cause, a fault file can be uploaded through the serial interface.
Please contact Precision Engine Controls Corporation for more details.
If after following the troubleshooting procedures, the user is unable to find the
cause of the problem, contact Precision Engine Controls Corporation for
assistance. See Section 8 for return information.

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 HFG2.0
Table 4-1: HFG2.0 Initial Installation Troubleshooting Chart
Symptom
Valve Inoperative – FAULT
alarm
Valve Inoperative -
NO FAULT alarm
Valve does not track fuel
demand
Valve does not hold
consistent position-
oscillates or dithers
No position feedback
No motor current feedback
Valve Operative- FAULT
alarm active
Valve Operative- OVER
TEMP alarm active
RS232 Interface
Inoperative
Valve Leaks when closed
4-2
Probable Causes
Power Wires not connected
No or low 120 VDC power
No RUN or Fuel demand input
No or low 120 VDC power
No Run or Fuel demand and
input
Varying fuel demand signal
No or low 120 VDC power
Position feedback wires not
connected
No or low 120 VDC power
Motor current wires not
connected
No or low 120 VDC power
Fault wiring incorrect
Internal FAULT
Fault wiring incorrect
Electronics or Motor winding
temperature out of range
Valve Jammed
Incorrect wiring
No or low 120 VDC power
COM1 not connected
Reset or Run ON
Poppet assembly fouled
Valve installed backwards
Corrective Action
Ensure RED and GREEN wires correctly
connected to Valve
Ensure 120 VDC Primary System Power at Valve
Ensure VIOLET and WHITE/VIOLET wires
correctly connected to Valve
Ensure 24 VDC RUN and fuel demand at Valve
Ensure BROWN and WHITE/BROWN wires
correctly connected to Valve
Ensure fuel demand > 4.1mA at Valve
Ensure stable fuel demand at the valve
Ensure 120 VDC Primary System Power at Valve
Ensure YELLOW and WHITE/YELLOW wires
correctly connected
Ensure 120VDC Primary System Power at valve
Ensure BLUE and WHITE/BLUE wires correctly
connected
Ensure 120 VDC Primary System Power at Valve
Ensure ORANGE and WHITE/ORANGE wires
correctly connected to Valve
Upload Fault File for exact failure cause
Ensure BLACK and WHITE/BLACK wires
correctly connected to Valve
Reduce External ambient temperature
Check for valve contamination
Ensure WHITE/ORANGE/YELLOW,
WHITE/ORANGE/BLUE,
WHITE/ORANGE/GREEN wires correctly
connected to Valve and laptop PC.
Ensure 120 VDC Primary System Power at Valve
Check laptop/PC com port
Remove Run or Reset Command
Stroke valve open and clear foul at orifice.
Ensure supply is connected to valve IN port.
 HFG2.0

Table 4-2: HFG2.0 In-Service Troubleshooting Chart

Symptom Probable Causes Corrective Action

No position feedback No 120 VDC Power Ensure 120 VDC at valve
Self protective shutdown Upload Fault File- check for current limit or
electronics or motor winding over temperature faults
Check for valve contamination

FAULT alarm Various Upload Fault File- clear indicated fault

OVER TEMP alarm Ambient temperature limit Allow valve to cool and re-start
exceeded
Reduce ambient or gas temperature

Electronics or Motor winding Check for valve contamination

temperature out of range
FAULT and OVERTEMP DSP or power supply failure Ensure 120VDC at valve.
alarm

For Troubleshooting purposes use Table 4-3 to verify the HFG2.0 electrical continuity integrity.

Disconnect the actuator power and digital harness connectors and use a digital multimeter (DMM) to check the
resistance values between the wires indicated on the table. If an open circuit is detected, send actuator to
Precision Engine Controls Corporation for test and repair.

WARNING:
Shock Hazard – Remove all power to actuator prior to continuity check

Table 4-3 ACT2000 Electrical Hook-Up Continuity Troubleshooting Chart

Function Actuator Wire Colors Resistance Value

DEMAND BRN and WHT/BRN 225:

RUN VIO and WHT/VIO 4.7K:

RESET GRY and WHT/GRY 4.7K:

POWER RED and WHT/RED High Impedance

MOTOR CURRENT BLU and WHT/BLU High Impedance

POSITION YEL and WHT/YEL High Impedance

FAULT ALARM ORN and WHT/ORN High Impedance

OVERTEMP BLK and WHT/BLK High Impedance

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 HFG2.0

5. MAINTENANCE

5.1 Cleaning
This section contains recommended HFG2.0 cleaning practices. Do not attempt
to follow any of these instructions until ALL steps have been read and
understood. Valve disassembly further to what is defined in this section will void
warranty.

WARNING:
Shock and Explosion Hazard – Do not remove actuator heat-sink cover.

WARNING:
Explosion Hazard – Serious injury could result if cleaning is performed
while valve is pressurized. Depressurize fuel system prior to valve
cleaning.

5.1.1 Required Test Equipment

x 0 to 24 VDC power supply, 0.5 A minimum – adjusted to 24 VDC
x 0 to 120 VDC power supply, 10 A minimum – adjusted to 120 VDC
x 0 to 20 mA current source
x Digital Volt Meter (DVM)
x Shop air

5.1.2 Recommended Solvents

Chlorinated solvents such as ethylene dichloride, or freon, will provide excellent
results in dissolving petroleum based contaminants such as tar, paraffin and
other hydrocarbons. Denatured alcohol may be used but will not be as effective.
Certain solvents will harm Viton o-ring seals contained within the valve. These
solvents are referred to as ketones. Acetone and MEK (Methyl-Ethyl Ketone) are
probably the best known. If it is absolutely necessary to use a ketone as a
cleaning agent, the exposure time must be limited to five (5) minutes maximum.
Shop air should be used to ensure that all residual solvent has evaporated.

5.1.3 On-Engine Cleaning

WARNING:
Explosion Hazard – This procedure involves handling explosive mixtures.
Proper precautions must be taken to ensure safe venting and dilution of
fuel gases to prevent explosion.

The HFG2.0 can be easily cleaned while on the turbine engine, as long as, the
valve OUTLET and drain ports are accessible.

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 HFG2.0

Perform the following steps to clean the valve metering elements:

x Depressurize fuel system and secure
x Remove turbine ignitor circuit breaker
x Apply 120 VDC system power
x Apply 20 mA fuel demand
x Apply RUN command. (Valve should open approximately 1.0 inch)
x Remove fuel valve drain plug
x Remove valve OUTLET fuel line
x Thoroughly clean around orifices and poppets using solvents listed in Section
5.1.2, cotton swabs and compressed shop air. Remove any visible particulate
using tweezers. Blow shop air through the lower orifice to guide excess
contaminants and solvents out the drain hole.

WARNING:
Injury Hazard – Keep fingers away from poppets and orifices during
cleaning.

x Slowly ramp fuel demand from 20 mA to 4 mA, and from 4 mA to 20 mA.

Verify valve feedback tracks fuel demand.
x Remove RUN command and 120 VDC system power.
x Install drain plug using PTFE tape. Tighten drain plug until plug end is below
valve surface.
x Reinstall valve OUTLET fuel line. Refer to Section 3.3.3 for proper bolt
torque.
x Install turbine ignitor circuit breaker.
x Pressurize fuel system.

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 HFG2.0

6. DECOMMISSIONING AND DISPOSAL

This section contains recommended HFG2.0 decommissioning and disposal
practices. It is for permanent removal or replacement of the installed product, with
no intentions of rework, overhaul, or to be used as spares.

For removal, follow proper lockout /tagout procedures and verify no live circuits:

x Disconnect power harness to product.

x Disconnect signal harness to product
x Verify fuel system is unpressurized.
x Remove inlet and outlet lines
x Use lifting equipment to support product and remove flange bolts

WARNING:
Lifting Hazard – Do not attempt to hand lift valve. Serious back injury may
result. Use appropriate lifting equipment.

Note: Follow local environmental codes in regards to disposal of electronic

components, specifically all electrolytic capacitors.

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 HFG2.0

7. GENERAL SPECIFICATIONS
Input Voltage
Minimum Voltage
Maximum Voltage
Maximum Current
Typical Transient Current
Typical Continuous Current
RUN and RESET Command Input
FAULT and OVERTEMP Output
Fuel Demand Analog Input
Position and Motor Current Feedback Analog
Maximum Common Mode Voltage
Temperature Limits
Maximum Operating Pressure
Proof Pressure
Minimum Controllable Flow (Natural Gas)
Maximum Controllable Flow
Step Response (10% to 90%)
Flow Accuracy
Environmental Rating
120 VDC
80 VDC
160 VDC
20 A
+20A < 60ms; +10A < 120ms; -5A < 100ms
< 1A
ON Voltage: 12 to 32 VDC; +24 VDC Nominal
ON Current: 6.5 mA Nominal @ 24 VDC
OFF Voltage: 3.5 VDC Maximum
OFF Current: 0.75 mA Maximum
OFF Voltage: 32 VDC Maximum
OFF Leakage Current: 150 PA Maximum
ON Current: 25 mA Maximum
ON Voltage Drop: 1 VDC Maximum @ 25 mA
Current: 4 to 20 mA; 40 mA Maximum
Voltage: 8 VDC Maximum
Internal Impedance: 200 :
Current: 4 to 20 mA
External Load Resistance: 500 : Maximum
r200 VDC User I/O to 120 VDC Return (less serial interface)
Operating Ambient: -40q C (-40q F) to +93q C (+200q F)
Operating Fuel: -40q C (-40q F) to +125q C (+257q F)
Storage: -40q C (-40q F) to +125q C (+257q F)
500 psig
2000 psig
15 pph (Configuration Dependent)
30,000 pph (Configuration Dependent)
100 ms
r 5% of flow point typical
CSA Type 3, European IP65

Vibration Mil-Std-810E, Category 4, 5 – 2000 Hz

Mean Time Before Unscheduled Removal 30,000 Hours
Electrical Connection Power Harness: (4) AWG 14, 90 in, ¾ NPT Conduit (EP)
Digital Harness: (17) AWG 20, 90 in, ¾ NPT Conduit (EP)
North American Certifications CSA (Canada and US) Class I, Div 1, Group B, C, D; T4

European Directive Compliance (CE Mark) EEx d, IIB+H2; T4

97/23/EC Pressure Equipment Directive (PED)
94/9/EC Potentially Explosive Atmospheres (ATEX)
73/23/EEC Low Voltage Equipment Directive (LVD)
98/37/EC Machinery Directive
89/336/EEC Electromagnetic Compatibility Directive (EMC)
Materials:
Actuator Housing 6061-T6 Anodized Aluminum
Valve Housings 6061-T6 Anodized Aluminum
316 Stainless Steel (Optional)
Conduit Union Zinc Plated Steel
Seals Viton and Teflon
Typical Dry Weight 100 lbs. Max (Aluminum Valve Housing)
190 lbs. Max (Stainless Steel Valve Housing)

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 HFG2.0

8. GLOSSARY

Term Definition
RUN Command A discrete 24 VDC signal that enables the HFG2.0 poppet to move.
RESET Command A discrete 24 VDC signal that causes the HFG2.0 internal program
(firmware) to initialize.
Engine Controller A user-provided control system that executes commands to the
HFG2.0 and accepts analog and discrete feedback.
Fuel Demand A 4mA to 20mA signal that commands the HFG2.0 to meter fuel
Fuel Demand Feedback A 4mA to 20mA signal that communicates the actual HFG2.0
position to the controller.
Motor Current Feedback A 4mA to 20mA signal that is proportional to the HFG2.0 motor
current.
FAULT alarm A discrete signal from the HFG2.0 that communicates an internal
failure. The controller will see an open circuit when a FAULT alarm is
active.
OVERTEMP alarm A discrete signal from the HFG2.0 that communicates an internal
over temperature; electronics or motor. The controller will see an
open circuit when an OVERTEMP alarm is active.

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