User Manual: XVG / eXVG Series Gas Fuel Metering Valve

User Manual
XVG / eXVG Series

Gas Fuel Metering Valve

SD-6011 Rev 2
July 2007
PRECISION ENGINE CONTROLS CORPORATION

This manual provides installation, maintenance, and operating instructions for the XVG/eXVG
Series of Gas Fuel Metering Valves.
Every attempt has been made to provide sufficient information in this manual for the
proper operation and preventive maintenance of the gas fuel-metering valve. Read
this manual in its entirety to fully understand the system.
Operating the XVG/eXVG Gas Fuel Metering Valve in accordance with instructions herein
ensures long term and reliable operation.

If you need additional information, please contact:

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

2007 PRECISION ENGINE CONTROLS CORPORATION. ALL RIGHTS RESERVED

TABLE OF CONTENTS
Purpose of This Guide ................................................................................................................................... iv
What the User Should Know......................................................................................................................... iv
Related Publications....................................................................................................................................... iv
1 INSTALLING THE XVG/eXVG.................................................................................................................. 1
1.1 Before Beginning..................................................................................................................................... 1
1.2 General Specification Summary............................................................................................................. 3
1.3 Mechanical Installation............................................................................................................................ 4
1.4 Electrical Connections............................................................................................................................. 10
2 UNDERSTANDING THE XVG/eXVG....................................................................................................... 25
2.1 System Description................................................................................................................................. 25
2.2 Versions of the XVG/eXVG.................................................................................................................... 26
2.3 Operating Modes of XVG/eXVG............................................................................................................ 34
2.4 Mechanical Functional Description ........................................................................................................ 36
2.5 Electrical Functional Description ............................................................................................................ 38
2.6 Identification Plate................................................................................................................................... 41
3 OPERATING THE XVG/eXVG.................................................................................................................. 45
3.1 Performance Factors............................................................................................................................... 45
3.2 Operating Modes..................................................................................................................................... 47
3.3 Feedback................................................................................................................................................. 51
3.4 Monitoring System Health....................................................................................................................... 54
4 MAINTAINING THE XVG/eXVG................................................................................................................ 55
4.1 Preventive Maintenance......................................................................................................................... 55
4.2 Corrective Maintenance.......................................................................................................................... 57
4.3 Calibration................................................................................................................................................ 62
4.4 Refurbishment ......................................................................................................................................... 62
5 TROUBLESHOOTING THE XVG/eXVG.................................................................................................. 63
5.1 Electrical Troubleshooting....................................................................................................................... 63
5.2 Retrieving The Fault File......................................................................................................................... 64
5.3 Fault Diagnosis........................................................................................................................................ 64
APPENDIX A: DECOMMISSIONING & DISPOSAL ...................................................................................... 71

PREFACE i

LIST OF FIGURES
Figure 1-1. Typical XVG/eXVG Gas Fuel System Installation........................................... 4
Figure 1-2. Alternate XVG/eXVG Gas Fuel System Installation........................................ 5
Figure 1-3. XVG Dimensions ............................................................................................... 6
Figure 1-4. eXVG Dimensions............................................................................................. 6
Figure 1-5. XVG/eXVG Dimensions with Harness as Electrical Interface......................... 7
Figure 1-6. XVG Mounting Provisions................................................................................. 8
Figure 1-7. eXVG Mounting Provisions............................................................................... 8
Figure 1-8. Wire Harness Connector for XVG/eXVG.......................................................10
Figure 1-9. Terminal Blocks for XVG/eXVG......................................................................11
Figure 1-10. Recommended Type of Explosion-Proof Connector...................................12
Figure 1-11. Ground Connections for XVG/eXVG............................................................13
Figure 1-12. Power Connection to Solenoid for XVG/eXVG...........................................14
Figure 1-13. Power Connection to Electronics for XVG/eXVG........................................15
Figure 1-14. Typical Analog Input Current Connection ....................................................17
Figure 1-15. Typical Analog Input Voltage Connection....................................................17
Figure 1-16. Typical Analog Output Current Connection .................................................18
Figure 1-17. Typical Analog Output Voltage Connection.................................................18
Figure 1-18. Typical Discrete Input Command Connection .............................................19
Figure 1-19. Typical Discrete Output Alarm Connection..................................................19
Figure 1-20. Typical RS232 Serial Interface Connection .................................................20
Figure 1-21. Wiring Shield Connections............................................................................23
Figure 2-1. Cross-sectional view of XVG/eXVG. ..............................................................26
Figure 2-2. Dynamic seal and scraper of XVG/eXVG. .....................................................27
Figure 2-3. Product Definition Number Details (sample)..................................................29
Figure 2-4. Exploded View of the XVG/eXVG...................................................................37
Figure 2-5. Partial Cutaway View of Breather Vent ..........................................................38
Figure 2-6. XVG/eXVG Electronics System Block Diagram............................................39
Figure 2-7. Typical Identification Plate for XVG, p/n 5002800-001 or -002.....................42
Figure 2-8. Typical Identification Plate for eXVG, p/n 5002800-003 or -004...................42
Figure 2-9. Typical Identification Plate for XVG, p/n 5002801-001 or -002.....................43
Figure 2-10. Typical Identification Plate for eXVG, p/n 5002801-003 or -004.................43
Figure 3-1. Stroke vs. Fuel Demand Curve.......................................................................48
Figure 3-2. Flow Rate vs. Fuel Demand Curve.................................................................50
Figure 3-3. Flow Rate vs. Outlet Pressure Curve.............................................................52
Figure 4-1. XVG Orifice Plate Removal.............................................................................59
II XVG/eXVG USER MANUAL

Figure 4-2. eXVG Orifice Plate Removal...........................................................................59
Figure 4-3. XVG Orifice Plate.............................................................................................61
Figure 4-4. eXVG Orifice Plate...........................................................................................61

LIST OF TABLES
Table 1-1. Connection List for XVG/eXVG Solenoid Power ............................................14
Table 1-2. Connection List for XVG/eXVG Electronics Power.........................................14
Table 1-3. Power Supply Requirements............................................................................15
Table 1-4. Signal Connections for XVG/eXVG, p/n 5002800-00x...................................16
Table 1-5. Signal Connections for XVG/eXVG, p/n 5002801-00x...................................16
Table 1-6. Computer COM Port Pin Outs .........................................................................20
Table 1-7. Recommended Wire Size for Harness............................................................21
Table 2-1. Part Numbers for XVG/eXVG..........................................................................27
Table 2-2. Model Numbers and Types..............................................................................28
Table 2-3. Operation Mode Configuration.........................................................................29
Table 2-4. Command (AICH0) Signal Configuration ........................................................30
Table 2-5. Analog Output Parameter Channel Configuration..........................................31
Table 2-6. Analog Output Signal Configuration ................................................................31
Table 2-7. Gas Constants Configuration...........................................................................32
Table 2-8. Max Flow Configuration....................................................................................32
Table 2-9. Calibration Curve ..............................................................................................33
Table 2-10. Electrical Interface...........................................................................................33
Table 2-11. Flange Interface..............................................................................................34
Table 3-1. Command (AICH0) Signal Configurations ......................................................45
Table 3-2. Command Signal Percentage Values .............................................................46
Table 3-3. Maximum Flow Area for XVG/eXVG...............................................................46
Table 3-4. Feedback (AOCH0 or AOCH1) Signal Configurations...................................52
Table 3-5. Feedback Parameter Configuration.................................................................53
Table 5-1. XVG/eXVG Expected Circuit Impedance........................................................64
Table 5-2. XVG/eXVG Initial Installation Troubleshooting Chart......................................66
Table 5-3. XVG/eXVG In-Service Troubleshooting Chart ................................................67
Table 5-4. System Health Parameters and Limits ............................................................69

PREFACE iii

Purpose of This Guide
This publication is designed to help the user install, operate, maintain and
troubleshoot the XVG/eXVG Gas Fuel Metering Valve.
What the User Should Know
To install, operate and troubleshoot the XVG/eXVG Gas Fuel Metering
Valve, it is necessary for the user to have a fundamental understanding
of:
Electronics concepts, such as voltage, current, and switches
Mechanical motion control concepts, such as inertia, torque,
velocity, distance, force
Related Publications
XView Software Operation Manual (SD-6014)

IV XVG/eXVG USER MANUAL

1 INSTALLING THE XVG/eXVG
1.1 Before Beginning
Inspection
The XVG/eXVG should be inspected immediately after unpacking. Check
for dings or dents or any other obvious signs of damage. Remove the
protective plug from the port for the wire harness (for Terminal Block
Electrical Interface option only) and check for any damage to the threads.
Examine the wire harness (for Wire Harness Electrical Interface options
only) for any signs of damage to the wire insulation.
In the event that any damage is detected, contact Precision Engine
Controls Corporation (PECC).
Note: Retain the metering valves original shipping container. In
the event of future transportation requirements, this
container will minimize any damage during shipment.
Recommended Installation Process

Review the general specifications
Mechanically connect the XVG/eXVG to the mounting surface
Connect Case Ground of the XVG/eXVG to System Ground
Remove the top cover of the XVG/eXVG per the instructions in
Figure 1-11 (for Terminal Block Electrical Interface option only)
Connect the XVG/eXVGs + and terminals or wires for the
Solenoid and Electronics 24VDC inputs to the users power
supplies or batteries
Connect the discrete and analog inputs and outputs of the
XVG/eXVG to the users controller
Test the installation

CH. 1: INSTALLING THE XVG/eXVG 1

Electrical Noise Guidelines
PECC has taken the following measures to reduce electrical noise with
the XVG/eXVG:
Filtering was added in the signal processing circuits.
Components in critical circuits were positioned to minimize
susceptibility.

An additional measure to reduce electrical noise is to:
Ensure that the XVG/eXVG is properly grounded, as per Section
1.4, Figure 1-11 of this manual.

Environmental Considerations
The XVG/eXVG operates satisfactorily with an ambient air temperature of
-40 C (-40 F) to +93 C (+200 F). The XVG/eXVG enclosure is
Canadian Standards Association (CSA) Type 4, European IP56.

2 XVG/eXVG USER MANUAL

1.2 General Specification Summary
PARAMETER VALUE
Power Input

Input Voltage, Nominal 24 VDC
Minimum Voltage 16 VDC
Maximum Voltage 32 VDC (maximum value for combined VDC and VAC components)
Maximum Ripple 2 VAC
Peak Current Solenoid: 10A
Electronics: 1A
Continuous Current Solenoid: 5A Maximum, 1.5A typical
Electronics: 0.5A Maximum, 130 mA typical

Inputs and Outputs

Analog Inputs
Current: 4 to 20 mA; 40 mA Maximum
Voltage: 0 to 5 VDC; 8 VDC Maximum
Input Impedance: 246 in Current Mode, 16.7k in Voltage Mode

Analog Outputs
Current: 4 to 20 mA
Voltage: 0 to 5 VDC
Load Resistance: 300 Max in Current Mode, 250 Min in Voltage Mode

Discrete Inputs
ON Voltage: 12 32 VDC, +24 VDC Nominal
ON Current: 1.5 mA Nominal @ 24 VDC
OFF Voltage: 3.5 VDC, Maximum
OFF Current: 0.75 mA, Maximum

Discrete Outputs
OFF Voltage: 32 VDC, Maximum
OFF Resistance: 200,000 Minimum
ON Resistance: 900 to 1100
ON Voltage: 32 VDC Maximum
Maximum Common Mode Voltage 200 VDC User I/O to 24 VDC Return

Performance
Maximum Operating Pressure XVG: 435 psig
eXVG: 500 psig
Proof Pressure XVG: 1740 psig
eXVG: 2000 psig
Minimum Delta P 0 psid (stroke mode), 20 psid (flow control mode)
Min. Controllable Flow (Natural Gas @ 59F) 12 lb
m
/ hour
Max. Controllable Flow (Natural Gas @ 59F
under sonic flow conditions, P
in
>1.9 P
out
)
XVG: 15,000 lb
m
/hour
eXVG: 20,000 lb
m
/hour
Step Response (10% to 90%) <100ms
Flow Accuracy 3% of full scale, typical
Mean Time Before Failure 30,000 Hours

Environmental
Temperature, Operating Ambient -40 C (-40 F) to +93 C (+200 F)
Temperature, Operating Fuel -20 C (-4 F) to +93 C (+200 F)
Temperature, Storage -40 C (-40 F) to +125 C (+257 F)
Environmental Rating Rated to NEMA 4 and European IP56
Humidity Meets Mil-Std-810F, 95% Relative Humidity (Non-Condensing)
Vibration and Shock Meets Mil-Std-810F, Vibration Category 22 (5 2000 Hz)
Meets Mil-Std-810F, Functional Shock, 20g peak, 11 ms duration
Meets Mil-Std-810F, Transit Drop

Certifications
North American Certifications CSA (Canada and US) Class I, Div 1, Group B, C, D; T4. File # 171042
European Directive Compliance (CE Mark)

II2G EEx d, IIB+H
2
; T4
97/23/EC Pressure Equipment Directive (PED)
94/9/EC Potentially Explosive Atmospheres (ATEX) KEMA 04ATEX2326
98/37/EC Machinery Directive
89/336/EEC Electromagnetic Compatibility Directive (EMC) Group 1 Class A
EN 50081-2 Emission
EN 61000-6-25 Immunity

Materials
Housing 6061-T6 Anodized Aluminum
316 Stainless Steel (Optional)
Seals PTFE and Viton

Dimensions XVG: 9.08 in x 5.80 in x 6.75 in
eXVG: 9.08 in x 7.70 in x 6.75 in

Weight XVG: 36 lbs. Max (Aluminum), ~60 lbs. (Stainless Steel)
eXVG: 38 lbs. Max (Aluminum), ~64 lbs. (Stainless Steel)

1.3 Mechanical Installation
This section describes proper XVG/eXVG installation. Ensure compliance
with the factory recommendations.
Typical Fuel System
The XVG/eXVG installs as part of a gas fuel system as shown in Figure
1-1. In this arrangement, the XVG/eXVG is located downstream from two
normally closed gas shut-off valves.
An alternate arrangement is shown in Figure 1-2. In this installation, the
XVG/eXVG is located between two normally closed gas shut-off valves.

Figure 1-1. Typical XVG/eXVG Gas Fuel System Installation

Figure 1-2. Alternate XVG/eXVG Gas Fuel System Installation
Fuel Filtering
For efficient valve operation, filter the fuel through a 40-micron absolute
filter before it reaches the valve. This extends the time between routine
maintenance. Locate the fuel filter as close as possible to the valve
INLET.
Dimensions
Figure 1-3 and Figure 1-4 show external dimensions for the XVG and
eXVG, respectively.
Mounting Considerations
The XVG/eXVG includes four (4) 5/16-24 UNF-3B mounting holes with
stainless steel heli-coil inserts for securing the controller enclosure. See
Figure 1-6 and Figure 1-7 for details about placement of mounting holes.
The XVG/eXVG can be mounted with any directional orientation, whether
horizontal, vertical, or at an angle. However, PECC recommends the
XVG/eXVG be mounted such that the Flow arrow on the body of the unit
(see Figure 1-6) is pointing up or down. This orientation has the solenoid
operating along a vertical axis and will thus reduce wear on the
XVG/eXVG.
High strength bolts (0.3125in. diameter) are required to secure the
controller enclosure to a user-provided mount bracket.
Note: Ensure adequate clearance is provided to the OUTLET and
to the electronics cover to facilitate installation and
maintenance.

Figure 1-3. XVG Dimensions

Figure 1-4. eXVG Dimensions

Note: To maintain flow control accuracy, ten-(10) pipe diameters
(15 inches) straight length minimum is recommended
upstream and downstream.
The aluminum-body XVG weighs approximately 36 lbs. The aluminum-
body eXVG weighs approximately 38 lbs. PECC recommends the use of
lifting equipment to lift the valve.

WARNING - Lift Hazard
Use special care when lifting by hand. Serious back injury may
result without appropriate lifting equipment.

Figure 1-5. XVG/eXVG Dimensions with Harness as Electrical Interface
(XVG shown)

Figure 1-6. XVG Mounting Provisions

Figure 1-7. eXVG Mounting Provisions

Pipe Connections
The standard pipe connections for the XVG/eXVG are:
XVG = SAE J518 -24 (1.5 inch), code 61
eXVG = SAE J518 -32 (2.0 inch), code 61
The valve bodies contain locking helical inserts. Contact Precision Engine
Controls Corporation for other connection options.
Note: Use only SAE conforming mating connections. Use of
non-conforming connections may change valve calibration.

Note: To maintain flow control accuracy, ten-(10) pipe diameters
(15 inches) straight length minimum is recommended
upstream and downstream.
Flange Bolts
Precision Engine Controls Corporation recommends the following bolts
and torque values:
XVG = 1/2 13 x 1-1/2, UNC-2A SAE Grade 5 or better.
eXVG = 1/2 13 x 1-3/4, UNC-2A SAE Grade 5 or better
Torque to 550 700 in-lb.

WARNING - Fuel Leakage Hazard
Do not over-torque fittings. Stripped threads or helical insert
damage may result.


1.4 Electrical Connections
The XVG/eXVG is suitable for use in hazardous locations. See the General
Specification Summary in Section 1.2 for certifications. Ensure compliance
with the factory recommendations, and that wiring is in accordance with
local requirements.
Electrical Interface Options
The XVG/eXVG is available in configurations with either an integral wire
harness or internal terminal blocks as the electrical interface.
Wire Harness Option
The XVG/eXVG is available with an integral 13-wire or 15-wire pigtail
harness as the electrical interface. The 13-wire harness is used with the
basic configurations of the XVG/eXVG. The 15-wire harness is used in
those configurations that require a second analog output channel. See
Figures 1-5 and 1-8 for representations of the wire harness connector.
See Section 2.2 for details about XVG/eXVG configurations.

Figure 1-8. Wire Harness Connector for XVG/eXVG

Terminal Block Option
The XVG/eXVG is available in configurations with internal terminal blocks
as the electrical interface. The top cover of the XVG/eXVG must be
removed to access the terminal blocks. See Figure 1-9 for a view of the
terminal blocks. See Figure 1-11 for cover-removal and installation
instructions.
Cutouts in heat sink
to allow access to
terminal blocks
Terminal Blocks
Internal
Ground Lug
Port For
Wire Harness
3/4 in. NPT
External Ground Lug
TOP VIEW
Cover Removed

Figure 1-9. Terminal Blocks for XVG/eXVG
Any XVG/eXVG with the terminal blocks as the electrical interface
features a threaded entry port (3/4in. NPT) to allow wiring between the
electronics enclosure of the unit and the power supplies and controller.
The XVG/eXVG is shipped with a plastic cap filling this entry port to
prevent foreign matter from entering the electronics enclosure.

Note: It is important that the cover and enclosure surfaces are free
from scoring and that the cover bolts are tightened with the
proper torque to maintain the explosion-proof rating.
Prior to installing a conduit into the threaded port, wrap Teflon tape on the
male threads of the conduit to ensure an adequate seal. Tape should
cover the entire thread area, with no more than two layers of tape on the
threads. The conduit should be tightened to a minimum of 45 ft-lbs. of
torque, with at least 5 full threads on the conduit engaged,
Explosion-Proof Wiring Installation
An explosion-proof seal, such as a hazardous location fitting or conduit
box with an approved seal, must be provided within 18 inches of the wire
entry port to comply with Canadian Standards Association (CSA), Class I,
Division 1, Group B, C and D requirements. This seal must also be
provided at the electronics enclosure wire entry per European Union (EU)
ATEX standards. The seal must be compliant and installed per local
European Union requirements. See Figure 1-10 for the recommended
type of explosion-proof connector for the XVG/eXVG.

Figure 1-10. Recommended Type of Explosion-Proof Connector (with wires
shown)
Ground Connections
The case of the XVG/eXVG features an external lug that is attached to
the housing with a screw and washers. This grounding lug is located on
the output side of the unit, just below the top cover, and it is unlabeled.
See Figure 1-11 for details and connection instructions. The grounding
lug, screw, and washers are provided.
The XVG/eXVG also features an internal grounding lug for those versions
that use the internal terminal blocks as the electrical interface. See Figure
1-11 for details and connection instructions.

Figure 1-11. Ground Connections for XVG/eXVG

Power Connections
The XVG/eXVG requires two power connections.
To the Solenoid
To the Electronics
Power Connection to Solenoid
The solenoid of the XVG/eXVG operates on a 24VDC (nominal), user-
provided input voltage. This voltage is supplied to the unit through either
the integral wire harness or the terminal blocks, depending on the
Electrical Interface configuration (see Section 2.2 for details).

FUNCTION WIRE COLOR TERM. #
Solenoid Power ORANGE 19
Solenoid Return RED 20
Table 1-1. Connection List for XVG/eXVG Solenoid Power

Figure 1-12. Power Connection to Solenoid for XVG/eXVG
Power Connection to Electronics
The electronics of the XVG/eXVG operate on a 24VDC (nominal), user-
provided input voltage. This voltage is supplied to the unit through either
the integral wire harness or the terminal blocks, depending on the
Electrical Interface configuration (see Section 2.2 for details).

FUNCTION WIRE COLOR TERM. #
Electronics Power VIOLET 21
Electronics Return BLUE 22
Table 1-2. Connection List for XVG/eXVG Electronics Power

Figure 1-13. Power Connection to Electronics for XVG/eXVG
WARNING
The user must ensure proper 24 VDC electronics power levels,
because the XVG/eXVG will NOT produce a fault signal if the 24 VDC
electronics input power voltage is outside the specified range.
Power Supply Requirements
Table 1-3 below lists the power supply requirements for the XVG/eXVG.

PARAMETER SOLENOID
Value
ELECTRONICS
Value
Voltage
Nominal
Minimum
Maximum

24 VDC
16 VDC
32 V (see Note)

24 VDC
16 VDC
32 V (see Note)
Ripple 2 VAC p-p, max 2 VAC p-p, max
Current
Maximum
Continuous , Max
Continuous, Typical

10 Amps
5 Amps
1.5 Amps

1 Amp
0.5 Amps
130 mA
Table 1-3. Power Supply Requirements
Note: The maximum voltage specification includes both DC and
AC (from ripple) components.

Signal Connections
The XVG/eXVG transmits and receives signals through either the integral
wiring harness or the terminal blocks, depending on the Electrical
Interface configuration (see Section 2.2 for details).
Signal Connections to Users Controller
Signals are sent between the XVG/eXVG and the users controller
through the integral 13-wire or 15-wire signal harness or through the
internal terminal blocks. See Tables 1-4 and 1-5 for the wire lists for these
harnesses, as well as the corresponding terminal numbers.

FUNCTION WIRE COLOR TERMINAL #
AICH0 (Demand) BROWN 1
AICH0 RTN (Demand RTN) GREEN 2
AOCH0 (Feedback) YELLOW 13
AOCH0 RTN (Feedback RTN) BLACK 14
FAULT ALARM WHITE / ORANGE 31
FAULT RTN WHITE / BLACK / ORANGE 32
Serial/TX Out A WHITE / ORANGE / BLUE 39
Serial/RX In A WHITE / ORANGE / YELLOW 40
Serial RETURN A WHITE / ORANGE / GREEN 41
Table 1-4. Signal Connections for XVG/eXVG, p/n 5002800-00x

FUNCTION WIRE COLOR TERMINAL #
AICH0 (Demand) BROWN 1
AICH0 RTN (Demand RTN) GREEN 2
AOCH0 (Feedback) YELLOW 13
AOCH0 RTN (Feedback RTN) BLACK 14
AOCH1 WHITE 15
AOCH1 RTN GREY 16
FAULT ALARM WHITE / ORANGE 31
FAULT RTN WHITE / BLACK / ORANGE 32
Serial/TX Out A WHITE / ORANGE / BLUE 39
Serial/RX In A WHITE / ORANGE / YELLOW 40
Serial RETURN A WHITE / ORANGE / GREEN 41
Table 1-5. Signal Connections for XVG/eXVG, p/n 5002801-00x


Note: For proper operation of the controller, the common mode
voltage between the control inputs and the power inputs
shall be less than 200 VDC.
Analog Inputs
The base XVG/eXVG configuration includes one analog input channel,
A/I CH0, which is dedicated as the Demand signal. Additional analog
input channels may be available as options (contact PECC for details).
The XVG/eXVG can be configured to accept the analog input signals in
either current form or voltage form.
The current range for an analog input is 4 to 20 mA, where 4mA
corresponds to a command of 0% and 20 mA corresponds to a command
of 100%. See Figure 1-14 for a typical analog input current connection.
The XVG/eXVG features two voltage configurations for the analog input
channels. The voltage range for analog inputs is 0 to 5 VDC, where 0
VDC corresponds to a command of 0% and 5VDC corresponds to a
command of 100%. The other voltage range for analog inputs is 1 to
5VDC, where 1 VDC corresponds to a command of 0% and 5VDC
corresponds to a command of 100%. See Figure 1-15 for a typical analog
input voltage connection.

Figure 1-14. Typical Analog Input Current Connection
CONTROLLER 0-5V OUTPUT
ANALOG IN RETURN
ANALOG IN
OVER
SUPPRESSOR
VOLTAGE
PROTECTION TRANSIENT
VOLTAGE
+
-
16.7K
+
-
XVG/eXVG
0-5V INPUT

Figure 1-15. Typical Analog Input Voltage Connection

Analog Outputs
The base XVG/eXVG configuration includes one analog output channel,
A/O CH0, which is dedicated as the Feedback signal. The XVG/eXVG
version with pressure sensors (p/n 5002801-00x) provides an additional
analog output, A/O CH1, for feedback. See Section 2.2 for details about
different versions of the XVG/eXVG.
The XVG/eXVG can be configured to provide the analog output signals in
either current form or voltage form. The same analog output signal form
will apply to all available analog outputs for a given configuration.
The current range for the analog outputs is 4 to 20 mA, where 4mA
corresponds to an output signal of 0% and 20 mA corresponds to an
output signal of 100%. See Figure 1-16 for a typical analog output current
connection.
The XVG/eXVG features three voltage configurations for the analog
output channels. The first voltage range for analog outputs is 0 to 5 VDC,
where 0 VDC corresponds to an output signal of 0% and 5VDC
corresponds to an output signal of 100%. The second voltage range for
analog outputs is 1 to 5VDC, where 1 VDC corresponds to an output
signal of 0% and 5VDC corresponds to an output signal of 100%. See
Figure 1-16 for a typical analog output current connection. The third
voltage range for analog outputs is 0 to -5 VDC, where 0 VDC
corresponds to an output signal of 0% and -5VDC corresponds to an
output signal of 100%. See Figure 1-17 for a typical analog output voltage
connection.

Figure 1-16. Typical Analog Output Current Connection

Figure 1-17. Typical Analog Output Voltage Connection

Discrete Inputs
The discrete input channel D/I CH0 is dedicated as the Run/Stop
command signal. D/I CH0 is shown on the nameplate but it is only
available as an option. Additional user-definable, discrete input channels
may also be available as options (contact PECC for details).
The discrete inputs are 24 VDC ON (High) and 0 VDC OFF (Low). See
Figure 1-18 for a typical discrete input connection.

Figure 1-18. Typical Discrete Input Command Connection
Discrete Outputs
The base XVG/eXVG configuration includes one discrete output channel,
D/O CH0, which is dedicated as the FAULT ALARM signal. Additional
user-definable, discrete output channels may be available as options
(contact PECC for details).
The discrete outputs are solid-state switches, which are normally closed.
The control system provides a current-limited voltage bias of 24 VDC.
See Figure 1-19 for a typical discrete output connection.

XVG/eXVG DISCRETE OUTPUT
DISCRETE OUT
CONTROLLER DISCRETE INPUT
DISCRETE OUT RTN
24VDC

Figure 1-19. Typical Discrete Output Alarm Connection
RS232 Serial Communications Interface
Signal levels for the serial communications input and output are per
RS232 standards. See Figure 1-20 for a typical RS232 interface
connection. See Table 1-6 for computer COM port pin-outs for RS232.

XVG/eXVG DISCRETE OUTPUT
RTN
COMPUTER
Rx
Tx
(WHT/ORN/GRN) [TERM #41]
(WHT/ORN/BLU) [TERM #37]
(WHT/ORN/YEL) [TERM #40]
COM1
RTN
Tx
Rx
TRANSCEIVER

Figure 1-20. Typical RS232 Serial Interface Connection

FUNCTION Standard 9-Pin
COM Port
Standard 25 -Pin
COM Port
Transmit (Tx) Pin 3 Pin 2
Receive (Rx) Pin 2 Pin 3
Ground (GND) Pin 5 Pin 7
Table 1-6. Computer COM Port Pin Outs
Note: The pin designations shown in Table 1-6 are for the COM
port on the computer. Make sure that the wiring to the
COM port mating connector correctly matches Transmit
from the XVG/eXVG to Receive on the computers COM
port, and vice versa.
Note: The maximum distance for serial connections is 50 ft. This
will typically only allow for local interface with a laptop PC.

Recommended Wiring
The recommended wiring is an 18-conductor shielded cable containing
twisted-pair wires with individual shields.
Ensure that all shielded cables are twisted conductor pairs with either a
foil or braided shield. PECC recommends Belden 9332 shielded twisted-
pair audio, broadcast and instrumentation cable. All signal lines should be
shielded to prevent picking up stray signals. Connect shields as shown in
Figure 1-21. Wire exposed beyond the shield should be as short as
possible.
The maximum resistance for the solenoid power loop should be one (1)
ohm. The maximum resistance for the electronics power loop should be
five (5) ohms. The maximum resistance for the signal wire loop should be
ten (10) ohms.
See Table 1-7 for recommended wire sizes.

DISTANCE TO
USERS POWER
/ CONTROLLER
SIGNAL
WIRE SIZE
(Minimum)
POWER
WIRE SIZE
(Minimum)
GROUND
WIRE SIZE
(Minimum)
1 to 125 ft. AWG 22, stranded AWG 16, stranded AWG 16, stranded
125 to 500 ft. AWG 16, stranded AWG 10, stranded Not Recommended
500 to 1000 ft. AWG 14, stranded AWG 7, stranded Not Recommended
> 1000 ft. Not Recommended Not Recommended Not Recommended
Table 1-7. Recommended Wire Size for Harness
Note: The XVG/eXVG terminal blocks will accept wire sizes from
18 AWG to 22 AWG. An external junction box must be
used if larger diameter wire is required.

CAUTION
This valve is 89/339/EEC EMC Directive compliant (CE mark) using
watertight, flexible conduit (plastic over steel) and Belden 9332
shielded, twisted pair-audio, broadcast and instrumentation cable.
Use of other conduit or wire invalidates EMC Directive compliance.
Do not connect 24 VDC power without current limiting (25 mA)
across digital or analog outputs.


Figure 1-21. Wiring Shield Connections

INTENTIONALLY BLANK


2 UNDERSTANDING THE XVG/eXVG
2.1 System Description
The XVG/eXVG is an electrically operated gas fuel-metering valve that
requires only 24 VDC power and an analog fuel Demand signal to
achieve basic operational capability. No pneumatic or hydraulic power is
required.
The flow tube and armature assembly is the only moving part in the
system. A solenoid and return spring combination is used to move the
flow tube assembly. Flow is metered between the flow tube and output
orifice in proportion to the flow tube position and resultant flow area. The
flow area ranges from zero with a Demand signal at 0% of its range to
maximum with a Demand signal at 100% of its range. See Figure 2-1 to
view the flow tube assembly and solenoid. A scraper and dynamic seals
are located around the flow tube to prevent the gas from entering the
housing assembly (see Figure 2-2). The flow tube closes around the
orifice seal when the fuel Demand signal is 0% or when solenoid power is
removed.
The XVG/eXVG is a force-balanced system. A solenoid actively provides
electro-magnetic force to open the valve based on the relative strength of
the Demand signal. This is counter-balanced by a return spring that
passively provides mechanical force to close the valve. The gas pressure
is balanced across the flow tube such that the solenoid force primarily
acts against the return spring.
When the Demand signal level increases, the solenoid provides additional
force on the flow tube assembly. The solenoid is now exerting more force
than the return spring, so the valve opens further until the spring force is
balanced with the solenoid force.
When the Demand signal level decreases, the solenoid provides less
force on the flow tube assembly. The solenoid is now exerting less force
than the return spring, so the valve closes further until the spring force is
balanced with the solenoid force.
The return spring acts as a fail-safe. It stores enough energy to fully close
the valve when Demand drops to a level corresponding to the 0% position
or if power to the solenoid or electronics is removed.
A linear variable differential transformer (LVDT) is directly connected to
the flow tube and provides tube-positioning feedback to the control loop in
the digital signal processor (DSP) to ensure accurate tube placement.
CH. 2: UNDERSTANDING THE XVG/eXVG 25

Optional pressure sensors at the input and output ports provide the ability
to determine flow. The XVG/eXVG can also be configured to track the fuel
Demand signal in proportion to measured mass flow. Another optional
configuration limits fuel mass flow by scaling the fuel Demand signal
according to pre-programmed maximum and minimum fuel limit levels.
See Section 3: Operating Modes of XVG/eXVG for details.

Figure 2-1. Cross-sectional view of XVG/eXVG.
2.2 Versions of the XVG/eXVG
Two numbers describe the configuration of a given XVG/eXVG:
Part Number
Product Definition Number (PDN)

Figure 2-2. Dynamic seal and scraper of XVG/eXVG.
Part Numbers
The part number for the XVG/eXVG is made up of two parts: the base
part number and the extension. For example, the part number 5002800-
001 has a base part number of 5002800 and an extension of -001

Base Part Number
The part number designates the specific version and corresponding bill of
material used to manufacture the XVG/eXVG. See Table 2-1

Base Part # Description Application

5002800
This is the baseline model of the XVG/eXVG.
The Demand signal is used to directly modulate
the flow tube assembly position. Flow is metered
between the flow tube and outlet orifice in
proportion to flow tube position and resultant flow
area. Includes only one analog output channel.

Fuel Regulation

5002801
This is mechanically equivalent to the baseline
model with the addition of pressure sensors at
the inlet port and outlet port. Includes two analog
output channels.
Flow Measurement
Flow Control
Flow Limiting
Table 2-1. Part Numbers for XVG/eXVG


Extension Numbers
The XVG/eXVG is available in two different models: the XVG and the
eXVG. The XVG is the base model. The eXVG is the larger flow-capacity
model.
The physical differences between the XVG and eXVG are that the eXVG
has:
larger inlet and outlet plates to accept 2.0 inch flanges (rather than
1.5 inch flanges with the XVG)
contoured inlet
larger output port

Both the XVG and eXVG are available in Main valve and Pilot valve form.
A Pilot-type XVG, for instance, is the same as the Main-type XVG, with
the exception that a larger flow body is used. This reduces the flow area
of the Pilot valve to approximately 60% of the flow area of the
corresponding Main valve. The result is that a Pilot valve will have finer
resolution but will only support lower flow levels than the corresponding
Main valve. See Section 3.1 for additional details.
The part number extension used to describe a valve indicates the model
and the type of the valve. See Table 2-2.

Part #
Extension
Model Type
-001 XVG Main
-002 XVG Pilot
-003 eXVG Main
-004 eXVG Pilot
Table 2-2. Model Numbers and Types
Product Definition Numbers
The Product Definition Number (PDN) numbering system defines the
specific XVG/eXVG setup and configuration. See Figure 2-3 for an
example of a PDN and its parameters.
The PDN is identified on the nameplate, as shown in Figures 2-7 through
2-10 at the end of this section.
The PDN and its associated parameters and values must be defined and
referenced in the procurement process of this product. Contact Precision
Engine Controls Corporation for assistance in defining this number and
its associated parameters and values for your application.


Figure 2-3. Product Definition Number Details (sample)
Operation Mode (MODE)
The XVG/eXVG can operate in four different modes, as described in
Table 2-3. The 5002800, the basic version of the XVG/eXVG, can only
operate in Stroke mode. The 5002801 can operate in all 4 modes.
See Sections 2.3 and 3.2 of this manual for additional information about
operation modes of the XVG/eXVG.

# Operation
Mode
Description
0 Stroke Valve position (stroke) is a direct function of command value
1 Flow
Measurement
Valve position (stroke) is a direct function of command value. Measured
flow is provided as an analog output signal, typically on AOCH1.
2 Flow Control Command signal specifies requested flow in PPH. Valve automatically
adjusts metering of the flow tube assembly to achieve flow as defined by
the command signal and scaled by the Max Flow parameter of the PDN.
3 Flow Limiting Command signal specifies requested flow in PPH based on a schedule
of max/min flow values at a number of outlet pressure values. Valve
automatically positions metering flow tube to achieve flow as defined by
the command signal and interpolated from the flow schedule.
Table 2-3. Operation Mode Configuration
Command Signal (CMD)
The Command Signal parameter in the PDN describes the signal format
and range of the fuel Demand signal used to control the XVG/eXVG. See
Table 2-4 for details.

# Command
Signal
Description
0 4 to 20 mA 4 mA = 0% command
20 mA = 100% command
1 0 to 5 VDC 0 VDC = 0% command
5 VDC = 100% command
2 1 to 5VDC 1 VDC = 0% command
Table 2-4. Command (AICH0) Signal Configuration
Analog Output Channels (AOCH0 & AOCH1)
Analog output channels 0 and 1 (AOCH0 and AOCH1) are feedback
signals. Two digits in the PDN describe each channel. The first digit
represents the parameter represented by the feedback signal on that
channel. See Table 2-5.
The second digit represents the signal configuration, both format and
range, for the feedback signal on that channel. See Table 2-6.
The PDN shown in Figure 2-2, for example, has the two digits 12 for
AOCH0. This means that the feedback signal on Channel 0 represents
the valve position and the signal is in Volts, with a range of 1 to 5VDC.

# Analog Output
Parameter
Description
0 Disabled The analog output channel is disabled.
1 Valve Position Output is scaled to report valve position. The output tracks Demand
under normal operation in Stroke and Flow Measurement modes.
2 Measured
Flow
Output is scaled to report measured flow:
Minimum = 0 pounds per hour (PPH)
Maximum = Max value specified in Maximum Flow Parameter
3 N/A Not applicable
4 Input Pressure
(psig)
Output is scaled as a function of measured input pressure:
Minimum = 0 psig
Maximum = 500 psig
5 Output
Pressure
(psig)
Output is scaled as a function of measured output pressure:
Minimum = 0 psig
Maximum = 500 psig
6 Gas Temp
(Celsius)
Output is scaled as a function of gas temp:
Minimum = 0 C
Maximum = 150 C
Table 2-5. Analog Output Parameter Channel Configuration

# Analog Output Signal
Configuration
Description
0 4 to 20 mA 4 mA = 0%
20 mA = 100%
1 0 to 5 VDC 0 VDC = 0%
5 VDC = 100%
2 1 to 5VDC 1 VDC = 0%
5 VDC = 100%
3 0 to 5VDC 0 VDC = 0%
5 VDC = 100%
Table 2-6. Analog Output Signal Configuration

Gas Constants (R & k)
The R parameter in the PDN represents the gas constant R for the gas
being regulated by the XVG/eXVG. The k parameter in the PDN
represents the specific heat ratio for the gas being regulated by the
XVG/eXVG.
These fuel properties vary for different gases. Flow measurement
accuracy is based on accurate correlation of these properties with the
media being measured. The Gas Constant numbers for R and k must
correlate with the gas being regulated by the XVG/eXVG. The gas to be
regulated must be defined in the procurement process for this product to
ensure that the proper values for the constants are used. See Table 2-7.

Gas Constant Description
R

(ft-lb
f
/ lb
m
-R)
Gas Constant
Air = 53.34
Natural Gas = 79.1
Propane = 35.04
k Specific Heat Ratio Cp/Cv
Air = 1.4
Natural Gas = 1.273
Propane = 1.12
Table 2-7. Gas Constants Configuration
Maximum Flow (MAX FLW)
Maximum flow capability is a function of gas pressure and temperature
conditions. Operating conditions must be carefully considered when the
Maximum Flow number is chosen for an application. See Table 2-8.

Maximum Flow Description
PPH X 1000 Units are kPPH. This parameter scales the analog output when
configured for measured flow.
Table 2-8. Max Flow Configuration

Calibration Curve (CAL CURVE)
Performance goals for flow and pressure for a given application are used
to empirically determine the stroke and nominal flow area (C
d
A) needed at
various points across the Demand signal range. The stroke values, and
their corresponding flow area values, are plotted relative to Demand
signal percentages (10%, 25%, 50%, 75%, and 100%, for instance) to
define performance curves. Precision Engine Controls Corporation
determines which calibration curve is necessary to achieve the
customers desired performance profile across the Demand signal range.
The Calibration Curve field in the PDN is used to identify the curve
number that has been used to calibrate the unit. See Table 2-9.

Field Description
Calibration Curve Desired fuel flow and/or stroke vs. command characteristic for valve.
Contact Precision Engine Controls Corporation for available flow
characteristics.
Table 2-9. Calibration Curve
Electrical Interface (ELECT)
The Electrical Interface parameter specifies which one of the three
electrical interface options has been used. See Table 2-10.

# Electrical
Interface
Description
0 Terminal Block
Only
Power and signal interfaces directly to the on-board terminal block.
1 13-Wire, EP
Harness
A thirteen-wire, explosion proof, pigtail harness is installed with the valve.
2 15-Wire, EP
Harness
A fifteen-wire, explosion proof, pigtail harness is installed with the valve.
Table 2-10. Electrical Interface

Note. Hazardous Location Requirement:

In order to comply with ATEX requirements, the user must
install an explosion-proof seal within 18 inches of the valve
enclosure exit when interfacing directly to the terminal block.
Flange Accessory (FLANGE)
The Flange Accessory parameter specifies which one of the three flange
accessory options has been used. See Table 2-11.

# Flange
Accessory
Description
0 None No adapters installed
1 MS Adapter Kit MS33786-20 Flange, (4-Bolt) (XVG Only)
2 ANSI 1.5in. SAE J518-24 TO ANSI #150 Flange (XVG Only)
Table 2-11. Flange Interface

Note. Contact Precision Engine Controls Corporation for details
on flange conversions.
2.3 Operating Modes of XVG/eXVG
The XVG/eXVG is available in four fully programmable operating modes.
The basic XVG/eXVG is configured to operate in stroke mode. Flow
measurement, flow control and flow-limiting modes are available as
optional configurations.
Stroke Mode
In stroke mode, the XVG/eXVG tracks the fuel Demand signal in
proportion to the flow tube assembly position. As Demand increases, the
solenoid exerts more force on the flow tube assembly, thus stroking open
the valve until it reaches the appropriate position while further

compressing the return spring. As Demand decreases, the solenoid
exerts less force on the flow tube assembly, thus allowing the return
spring to stroke closed the valve until it reaches the appropriate position.
Positioning feedback from an LVDT is sent to a control loop to help
control the flow tube assembly position.
Flow is metered between the flow tube and orifice in proportion to flow
tube position and the corresponding flow area (C
d
A). The flow area
ranges from zero at 0% to maximum at 100%.

Flow Measurement Mode
The flow measurement mode option includes two gas pressure sensors
and a gas temperature sensor.
In flow measurement mode, the valve tracks the fuel Demand signal as
outlined in the stroke mode. The mass flow is determined using the valve
effective flow area, pressure and temperature sensor information, and the
gas constants described in the PDN.
An analog feedback signal that is proportional to measured mass flow is
typically provided on an analog output. The minimum feedback signal
represents zero flow. The maximum feedback signal represents
maximum mass flow. This feedback signal is scaled by the Max Flow
parameter in the PDN. Mass flow may differ from Demand depending on
flow conditions.
Flow Control Mode
In flow control mode, the valve tracks the fuel Demand signal in proportion
to measured mass flow.
An analog feedback signal that is proportional to measured mass flow is
typically provided on an analog output. The minimum feedback signal
represents zero flow. The maximum feedback signal represents
maximum mass flow. This feedback signal is scaled by the Max Flow
parameter in the PDN.
Note. Flow Control Mode will not initiate until a positive 20 psid
(inlet greater than outlet) is measured across the valve.
As fuel Demand increases or decreases the controls energize the
solenoid coil to the appropriate level and the flow tube strokes open or
closed until the measured mass flow equals the commanded mass flow.
As fuel Demand, pressure or temperature change, a control loop adjusts
the flow tube position to establish the requested mass flow.

Flow Limiting Mode
The optional flow-limiting mode prevents over- or under-fueling of a
turbine engine. Pre-programmed schedules for maximum and minimum
fuel mass flow relative to output pressure are used to determine how the
fuel Demand signal is to be tracked.
As fuel Demand increases or decreases the control electronics read the
outlet pressure and scale mass flow according to the Demand signal level
and fuel limit schedules. The flow tube assembly position is controlled to
establish the requested limit for mass flow.
Analog feedback is in terms of measured mass flow. Minimum feedback
is zero flow. Maximum feedback is the preprogrammed maximum mass
flow.
2.4 Mechanical Functional Description
See Figure 2-4 for a view of the assemblies described below.
Housing Assembly
The housing assembly is a two-piece unit that consists of a machined
valve body and an electronics enclosure. The enclosure attaches to the
valve body with four attachment screws.
A breather is incorporated into the housing assembly in order to vent any
pressure build-up within the entire assembly. If any dynamic seal leaks
occur, the resultant gas build-up will vent to ambient beginning at 1 or 2
psig. See Figure 2-5.
Solenoid Motor Assembly
The solenoid motor assembly consists of a flow tube and armature
assembly, coil, housing and damping system. This electro-magnetic
assembly contains the only moving part within the valve assembly.
Fuel flow is regulated by changing the position of the flow tube assembly.
Inlet Plate Assembly
The inlet plate assembly consists of a machined plate containing a linear
variable differential transformer (LVDT), dynamic seal, scraper,
temperature sensor, and optional pressure sensor.
The scraper is designed to scrape contaminants from the flow tube. (See
Figure 2-2) An o-ring seal prevents water intrusion. An SAE J518 24
(1.50 inch), Code 61 pipe interface is machined into the inlet plate for the
XVG. An SAE J518 -32 (2.0 inch), code 61 pipe interface is machined into
the outlet plate for the eXVG. Other pipe interfaces are optional.


Outlet Plate Assembly
The outlet plate assembly is a machined plate containing a dynamic seal
and an optional outlet pressure sensor.
The plate is o-ring sealed to prevent water intrusion. An SAE J518 24
(1.50 inch), Code 61 pipe interface is machined into the outlet plate for the
XVG. An SAE J518 -32 (2.0 inch), code 61 pipe interface is machined into
the outlet plate for the eXVG. Other pipe interfaces are optional as
attachments.
Orifice Plate
The orifice plate is a machined assembly containing an orifice seal and
flow divider. The orifice seal prevents flow leakage into the outlet.
Cover
The cover is a machined, o-ring sealed plate that allows access to the
electronics terminal blocks.

Figure 2-4. Exploded View of the XVG/eXVG


Figure 2-5. Partial Cutaway View of Breather Vent
2.5 Electrical Functional Description
The XVG/eXVG contains an on-board, digitally controlled electronic
assembly. The assembly contains analog-to-digital (A/D) converters, a
digital signal processor (DSP), power supplies, and system isolation and
conditioning circuits. Figure 2-6 shows a block diagram of the electronic
system.
Control Electronics
The control electronics assembly contains two electronic assemblies. The
control electronics are located within the housing assembly and are
accessible via the cover.
The control electronics assembly internally interfaces with the motor and
LVDT along with temperature sensors and optional pressure sensors.
External interfaces include analog, discrete and serial data. A digital
signal processor (DSP) controls all valve functions.
The control electronics interfaces with the engine control system and
power supply. The assembly incorporates analog and discrete inputs and
outputs, and a serial interface. It also provides signal conditioning for all
internal analog and discrete I/O, as well as LVDT and sensor inputs.
The digital signal processor (DSP) provides main control functions. All
serial communication, PID control, health monitoring, A/D conversion and
solenoid motor control is handled within the processor. An external
watchdog IC is used to monitor the DSP. This IC also monitors the supply
voltage to the DSP and will independently shut down the valve to close

position in case of DSP catastrophic failure, low voltage, brownout
condition, firmware problems and system hang conditions.
The DSP converts analog inputs to digital counts for use in the control
functions. The analog outputs are converted from digital counts and
output to the user.
A 10 kHz excitation signal is generated within the DSP to drive the LVDT.
The LVDT output is signal conditioned and converted for digital position
measurement.
A control signal is sent to the solenoid drive circuit. Solenoid motor current
is varied to control flow tube movement. Solenoid motor current feedback
is provided to the DSP through isolation circuits.
Signals from temperature sensors and optional pressure sensors are
converted to digital counts and used in the control functions.

Figure 2-6. XVG/eXVG Electronics System Block Diagram

Power
The XVG/eXVG operates on nominal 24 VDC input power. Two 24 VDC
inputs are required. The electronics input provides power to the control

electronics. The solenoid input provides power to the solenoid. Both
power inputs are required for system functionality.
The control electronics internal power supply isolates and conditions the
24 VDC input and converts it into 3.3 VDC, +15 VDC and 15 VDC. The
internal power supply filters and protects against noise transients and
reverse voltage. The internal power supply is isolated from the solenoid
power.

Analog Inputs/Outputs
The XVG/eXVG receives analog inputs from an external, user-provided
controller and also provides analog outputs. The XVG/eXVG includes a
single analog input that is dedicated for the fuel Demand control signal.
The base XVG/eXVG (p/n 5002800-xxx) provides a single analog output
for feedback. The XVG/eXVG option with pressure sensors (p/n 5002801-
xxx) provides two analog outputs for feedback. Refer to Section 1:
Installing the XVG/eXVG, for typical connections. Contact Precision
Engine Controls Corporation regarding applications that require additional
analog input and output.
The analog input can be configured to operate with any of three different
signal formats or ranges, as described in Table 2-4. The two analog
output channels can be configured independently to operate with any of
four different signal formats, ranges or polarities as described in Table 2-
6. Refer to Section 1.2: General Specification Summary, for load values.
Analog Input Channel 0 (AICH0) is configured for the fuel Demand signal.
Analog Output Channel 0 (AOCH0) is typically configured for the valve
position feedback signal. Analog Output Channel 1 (AOCH1) is typically
configured for the flow measurement feedback signal. See Section 2.2:
Versions of the XVG/eXVG (PDN) for a description of how the valve can
be configured.
Discrete Inputs/Outputs
Discrete Input Channel 0 (DICH0) is not currently implemented. Discrete
Output Channel 0 (DOCH0) is the Fault alarm which is configured as Trip
to Open on a fault condition. These discrete interfaces are optically
isolated. Refer to Section 1: Installing the XVG/eXVG, for a typical
connection.
Serial Interface
The XVG/eXVG contains a single, optically isolated RS232 serial
communication interface. The serial interface communicates set-up
parameters, performance conditions and fault diagnostics. Refer to
Section 1: Installing the XVG/eXVG, for a typical connection.


2.6 Identification Plate
A product identification plate is attached to the XVG/eXVG housing
assembly. See Figures 2-7 through 2-10 for typical identification plates
used with the different versions of the XVG/eXVG.
The identification plate lists model designation, product part number,
revision and unit serial number. Hazardous area operation, certification
and electrical wiring interface information is also provided.

Figure 2-7. Typical Identification Plate for XVG, p/n 5002800-001 or -002

Figure 2-8. Typical Identification Plate for eXVG, p/n 5002800-003 or -004


Figure 2-9. Typical Identification Plate for XVG, p/n 5002801-001 or -002

Figure 2-10. Typical Identification Plate for eXVG, p/n 5002801-003 or -004

INTENTIONALLY BLANK


3 OPERATING THE XVG/eXVG

3.1 Performance Factors
The following factors are used to describe, affect, or achieve the desired
performance for the XVG/eXVG.
Demand Signal
The analog signal (AICH0) is the only signal used to control the
performance of the XVG/eXVG. It is also referred to as the fuel Demand
signal. The XVG/eXVG can be configured to accept one of three different
command signal formats, as described in Table 3-1 below. The command
signal format used for a unit is described in its PDN, as described in
Section 2.2 of this manual.

Command
Signal
Description
4 to 20 mA 4 mA = 0% command
20 mA = 100% command
0 to 5 VDC 0 VDC = 0% command
1 to 5VDC 1 VDC = 0% command
Table 3-1. Command (AICH0) Signal Configurations
Command signal levels are often referred to as percentages of their
ranges rather than as absolute values. Table 3-2 lists percentage values
for the three command signal formats supported by the XVG/eXVG.
CH. 3: OPERATING THE XVG/eXVG 45

%
of Range
4 to 20 mA 0 to 5 V 1 to 5 V
0% 4 mA 0 V 1.0 V
10% 5.6 mA 0.5 V 1.4 V
20% 7.2 mA 1.0 V 1.8 V
30% 8.8 mA 1.5 V 2.2 V
40% 10.4 mA 2.0 V 2.6 V
50% 12 mA 2.5 V 3.0 V
60% 13.6 mA 3.0 V 3.4 V
70% 15.2 mA 3.5 V 3.8 V
80% 16.8 mA 4.0 V 4.2 V
90% 18.4 mA 4.5 V 4.6 V
100% 20 mA 5.0 V 5.0 V
Table 3-2. Command Signal Percentage Values
What the command signal is actually controlling depends on the operating
mode for which the XVG/eXVG is configured.
Flow Area
The only moving part in the XVG/eXVG is the flow tube assembly. The
position and movement of the flow tube assembly are referred to as the
stroke of the valve. The XVG/eXVG has a maximum stroke of 0.250in.
The position of the flow tube assembly determines the actual amount of
area through which the fuel can flow. When the position is at 0.0in., the
flow area is zero because the valve is closed and no gas can flow. When
the position is at its maximum value of 0.250in., the valve is fully open and
the flow area is at its maximum.
The maximum flow area for the XVG/eXVG is an indication of its fuel-flow
capacity. Table 3-3 lists the maximum flow area for each version of the
XVG/eXVG.

Version of Valve Maximum Flow Area (in
2
)
C
d
A (sonic)
XVG Main 0.49
XVG Pilot 0.32
eXVG Main 0.60
eXVG Pilot 0.32
Table 3-3. Maximum Flow Area for XVG/eXVG

Calibration Curves
Performance goals for flow and pressure for a given application are used
to empirically determine the stroke and nominal flow area (C
d
A) needed at
various points across the Demand signal range. The stroke values, and
their corresponding flow area values, are plotted relative to Demand
signal percentages (10%, 25%, 50%, 75%, and 100%, for instance) to
define performance curves.
While the XVG/eXVG has a full-range stroke capability of 0 to 0.250
inches, some applications may only require that a portion of this range,
such as 0 to 0.130 inches, be used.
Other parameters that are used in defining calibration curves may include
minimum and maximum values for inlet pressure, outlet pressure, flow
rate, and feedback percentage.
Precision Engine Controls Corporation determines the proper calibration
curve, and other parameters, necessary to achieve the customers
desired performance profile across the Demand signal range for a
particular application. A calibration curve is used for every XVG/eXVG
and is incorporated into the PDN (see Section 2.2 for details).

3.2 Operating Modes
The XVG/eXVG has four operating modes:
Stroke
Flow Measurement
Flow Control
Flow Limiting

The operating mode of a XVG/eXVG determines how commands are
processed.
Stroke Mode
In Stroke Mode, the Demand signal directly controls the position of the
flow tube assembly. The LVDT provides precise feedback about the flow
tube position to the electronics of the XVG/eXVG, thus allowing the stroke
to accurately track the Demand signal.


Demand Signal
A Demand signal of 0% will move the flow tube assembly to the minimum
position, which results in a closed valve.
A Demand signal of 100% will move the flow tube assembly to the
maximum position of its range, as determined by the calibration curve for
the unit.
The calibration curve determines the flow tube position for Demand signal
levels between 0% and 100%. See Figure 3-1 for a representation of
Stroke vs. Demand signal performance.

Figure 3-1. Stroke vs. Fuel Demand Curve
Flow Measurement Mode
A XVG/eXVG in Flow Measurement mode processes commands in the
same manner as a XVG/eXVG in Stroke mode. The Demand signal
directly controls the position of the flow tube assembly. The LVDT
provides precise feedback about the flow tube position to the electronics
of the XVG/eXVG, thus allowing the stroke to accurately track the
Demand signal.
Pressure sensors at the input and output ports, in conjunction with the
temperature sensor, provide the means to measure flow rate. The
XVG/eXVG uses pressure and temperature information from the sensors,
in conjunction with the gas constants defined in the PDN, to calculate the
flow rate.

Demand Signal
A Demand signal of 0% will move the flow tube assembly to the minimum
position, which results in a closed valve.
A Demand signal of 100% will move the flow tube assembly to the
maximum position of its range, as determined by the calibration curve for
the unit.
The calibration curve determines the flow tube position for Demand signal
levels between 0% and 100%. See Figure 3-1 for a representation of
Stroke vs. Demand signal performance.

Flow Control Mode
The Demand signal controls the flow rate for XVG/eXVG units in Flow
Control mode. XVG/eXVG units in Flow Control mode include the same
pressure and temperature sensors described in Flow Measurement
mode, allowing for continual flow-rate detection.
When the Demand signal changes, the XVG/eXVG compares the
commanded flow rate to the measured flow rate. The difference between
the commanded and measured flow rates, known as the flow error, is
used to determine the position set point. The XVG/eXVG initiates a stroke
to move the flow tube assembly to the new position, which will in turn
have a flow rate closer to the commanded flow rate. If any flow error is
detected after the move, the XVG/eXVG will change the position set point
again, causing another position adjustment. The XVG/eXVG will continue
adjusting the flow tube assembly position until the measured flow rate
matches the commanded flow.

Demand Signal
A Demand signal of 0% will set the flow rate at 0 kPPH, resulting in the
valve closing.
A Demand signal of 100% will set the flow rate to the units maximum flow
rate, depending on pressure and temperature conditions.
The calibration curve used for a XVG/eXVG unit in Flow Control mode is
a linear stroke for Demand signal levels between 0% and 100%.
See Figure 3-2 for a representation of Flow Rate vs. Demand signal
performance.

Figure 3-2. Flow Rate vs. Fuel Demand Curve
Flow Limiting Mode
The Demand signal also controls the flow rate for XVG/eXVG units in
Flow Limiting mode. XVG/eXVG units in Flow Limiting mode include the
same pressure and temperature sensors described in Flow Measurement
mode, allowing for continual flow-rate detection.
Flow Limiting mode requires that the maximum and minimum flow rates
be pre-defined for a range of outlet pressures. The XVG/eXVG uses this
information to associate a specific range of allowable flow rates with each
outlet pressure in the defined range. The Demand signal level and the
outlet pressure determine the commanded flow rate.
When the Demand signal changes, the XVG/eXVG uses the outlet
pressure to determine the flow-rate that corresponds to the new Demand
signal under the existing conditions. The XVG/eXVG compares the
commanded flow rate to the measured flow rate. The difference between
the commanded and measured flow rates, known as the flow error, is
used to determine the position set point. The XVG/eXVG initiates a stroke
to move the flow tube assembly to the new position, which will in turn
have a flow rate closer to the commanded flow rate. If any flow error is
detected after the move, the XVG/eXVG will change the position set point
again, causing another position adjustment. The XVG/eXVG will continue
adjusting the flow tube assembly position until the measured flow rate
matches the commanded flow.

Demand Signal
At a given outlet pressure, a Demand signal of 0% will set the flow rate to
the minimum flow rate defined for that outlet pressure based on the
calibration curve information.
At a given outlet pressure, a Demand signal of 100% will set the flow rate
to the maximum flow rate defined for that outlet pressure based on the
flow-limiting curve information.
Flow rates for Demand signal levels between 0% and 100% are linearly
interpolated between the minimum and maximum defined flow rates for
that outlet pressure.
Maximum flow rates for outlet pressures that have not been explicitly
defined are linearly interpolated between maximum flow rates for the
closest outlet pressures that have been defined.
Minimum flow rates for outlet pressures that have not been explicitly
defined are linearly interpolated between minimum flow rates for the
closest outlet pressures that have been defined.
The pre-defined maximum and minimum flow rate vs. outlet pressure
information is part of the calibration information for a XVG/eXVG unit in
Flow Limiting mode. PECC determines the proper calibration curve to use
for each application based upon the customers desired flow rate
characteristics. Contact PECC for details.
See Figure 3-3 for a representation of Flow Rate vs. Outlet Pressure
curves that are used in Flow Limiting mode.

3.3 Feedback
The XVG/eXVG offers either one or two analog output channels,
depending on the configuration. Units with the base part number
5002800 have one analog output channel, A0CH0. Units with the base
part number 5002801 have two analog output channels, A0CH0 and
A0CH1. Each of the analog output channels on the XVG/eXVG can be
configured independently to use one of four different feedback signal
formats, as described in Table 3-4. The feedback signal format used for
each analog output of a unit is described in its PDN, as described in
Section 2.2 of this manual.


Figure 3-3. Flow Rate vs. Outlet Pressure Curve (example)

Command
Signal
Description
4 to 20 mA 4 mA = 0%
20 mA = 100%
0 to 5 VDC 0 VDC = 0%
5 VDC = 100%
1 to 5VDC 1 VDC = 0%
5 VDC = 100%
0 to 5VDC 0 VDC = 0%
5 VDC = 100%
Table 3-4. Feedback (AOCH0 or AOCH1) Signal Configurations

The analog outputs can also be configured to provide feedback for five
different parameters. See Table 3-5 for a description of these parameters.
Units with the base part number 5002800 do not have pressure sensors,
so they can only provide feedback for Stroke or Gas Temperature. Units
with the base part number 5002801 have pressure sensors, so they can
provide feedback for any of the five parameters shown in Table 3-5.
Analog output AOCH0 is typically configured for Stroke feedback. Analog
output AOCH1 is typically configured for Flow Measurement feedback.
(A0CH1 is disabled on units with the base part number 5002800.) The
analog outputs can be configured for any of the five parameters shown in
Table 3-5, but deviations from the typical analog output configuration
must be indicated in the PDN when the unit is being ordered.

Analog Output
Parameter

DESCRIPTION

Stroke
Output is scaled to report the flow tube assembly position. Output
tracks Demand signal under normal operation in Stroke Mode and
Flow Measurement Mode.

Measured Flow
(kPPH)
Output is scaled to report measured flow:
Minimum = 0 PPH
Maximum = Max. value specified in Maximum Flow Parameter in PDN

Input Pressure
(psig)
Output is scaled as a function of measured input pressure:
Minimum = 0 psig
Maximum = 500 psig

Output Pressure
(psig)
Output is scaled as a function of measured output pressure:
Minimum = 0 psig
Maximum = 500 psig

Gas Temp
(Celsius)
Output is scaled as a function of gas temp output pressure:
Minimum = 0 C
Maximum = 150 C
Table 3-5. Feedback Parameter Configuration

3.4 Monitoring System Health
The firmware program continuously monitors system health while the
XVG/eXVG is powered. If any of the critical health parameters are out of
the normal operating range, the XVG/eXVG electronics shut down the
unit and output a discrete FAULT alarm to the users controller. The
XVG/eXVG firmware also captures the fault data in an EEPROM.
FAULT Alarm
The FAULT alarm is a non-latching, solid-state contact from the
XVG/eXVG. Upon power-up, the FAULT circuit closes and stays
CLOSED in the normal operating condition. When the XVG/eXVG detects
a system fault, it opens the FAULT circuit.
If a critical system fault is detected the XVG/eXVG will enter a shutdown
state immediately. Non-critical faults will trigger the FAULT alarm as a
warning, but they will not cause a shutdown. See Table 5-4 of this manual
for a list of faults, possible causes, and the action taken when the fault is
detected (shutdown or warning).
A fault file can be uploaded from the XVG/eXVG using PECCs
proprietary XView software via the RS232 interface. See Section 5.2. The
fault file will provide fault information and possible causes. Contact
Precision Engine Controls Corporation to request this software.
Shutdown State
The Shutdown State is a safety condition that will prevent uncontrolled
operation of the valve. In a shutdown state the Pulse Width Modulator
(PWM) output from the DSP is removed so the valve will close and not
respond to command. The XVG/eXVG will not respond to the Demand
signal until the faulting condition is removed.
If the faulting condition is not known, try cycling power OFF then ON. If
the problem that caused the shutdown is no longer present, the
XVG/eXVG will return to a normal operating state. If the problem is still
present, the XVG/eXVG will resume a shutdown state. It is important to
retrieve the fault file from the XVG/eXVG in either situation to determine
the nature of the fault and possible causes. See Section 5.2 of this
manual for details about how to upload the fault file from the XVG/eXVG.
Note: The only way to exit the Shutdown State is to first remove
the condition that caused it. Once the faulting condition is
removed, the XVG/eXVG will function normally.


4 MAINTAINING THE XVG/eXVG
The XVG/eXVG is designed for long, reliable life. Some regular minor
maintenance can extend the service life of the equipment and prevent
serious problems from occurring
Preventative maintenance actions, such as normal, routine inspection and
cleaning instructions, are described in the Section 4.1 below. Perform
recommended maintenance periodically and in parallel with normal
turbine maintenance schedules. No additional engine downtime should
be expected.
Corrective maintenance actions, those minor repairs that can be
performed in the field in the unlikely event that the XVG/eXVG
malfunctions, are described in Section 4.2. These are the only repairs that
can be performed by the customer.
If corrective maintenance does not fix any malfunction, the valve must be
sent to Precision Engine Controls Corporation for repair or replacement.
Contact Precision Engine Controls Corporation for Return Material
Authorization (RMA) before shipping the valve back to the factory.
Note. Keep a maintenance log for the XVG/eXVG fuel-metering
valve. A service history makes it easier to establish a
maintenance schedule.
4.1 Preventive Maintenance
This section contains information and instructions for routine
maintenance. By performing these procedures at regular intervals you
can extend the service life of the equipment and prevent serious problems
from occurring.
Visual Inspection
Perform the following visual examination every week.
Inspect the valve exterior for loose or broken parts. Pay particular
attention to wires, shields and connectors.
Thoroughly inspect wires and cables for wear, fraying, or damage.
Repair any damaged areas you may find.
Check fuel lines and fittings for leaks or damage.
CH. 4: MAINTAINING THE XVG/eXVG 55

External Cleaning
Clean the valve exterior every 60 to 90 days, or more often, as the
environment dictates. This cleaning aids the visual inspection and
prevents unwanted dirt build-up.
Be sure to depressurize the fuel system before cleaning the valve.
The XVG/eXVG can be externally cleaned with a jet of water. The
XVG/eXVG enclosure is environmentally rated to NEMA 4 and European
IP56. As such, the XVG/eXVG can withstand a strong water jet directed
at its enclosure with no harmful effects. The test conditions necessary to
secure the environmental rating involved a jet nozzle with an inside
diameter of 12.5-mm splashing a volume of 100 liters per minute from a
distance of 2.5-3 meters from all sides of the enclosure for duration of 3
minutes.
Precision Engine Controls Corporation recommends that the flow rate of
the water jet used in the cleaning, as well as the duration of the cleaning,
not exceed the flow rate and duration used in the environmental rating
test.
Note. Minimize exposure to water during routine maintenance.

WARNING - Explosion Hazard

Serious injury may result if cleaning is performed while valve is
pressurized. Depressurize fuel system prior to valve cleaning.
The following procedure is an alternate method of cleaning the
XVG/eXVG.
Depressurize the fuel system prior to cleaning the valve.
Remove loose dirt with low pressure, clean dry air.
Carefully wipe exterior surfaces with clean cloth and either mild
soap and water or ethyl alcohol.

Fuel Filter Replacement
Use of recommended fuel filters helps prolong equipment service life.
Therefore, be sure to replace fuel filters at least every six-(6) months.

4.2 Corrective Maintenance
This section describes corrective maintenance allowable in the field. Refer
to Section 5: Troubleshooting, for more information.
Required Items
Corrective maintenance actions require the following items:
Precision Engine Controls Corporation special tool;
P/N 5002994-001 for the XVG or P/N 5003948-001 for the eXVG
Orifice seal replacement kit; P/N 5003261-001 or 002 (XVG
only)
O-ring; P/N M83248/1-034 (XVG), P/N M83248/2-037 (eXVG),
O-ring lubricant, such as Parker O-Lube
Solvents for cleaning (see below for recommended solvents)
Recommended Solvents
Chlorinated solvents such as ethylene dichloride, Freon or similar
chemicals are excellent for dissolving petroleum-based contaminants
such as tar, paraffin and other hydrocarbons. Denatured alcohol may also
be used, but it will not be as effective as the chlorinated solvents.
Certain ketone solvents, such as Acetone and MEK (Methyl-Ethyl
Ketone), can damage the Viton
o-ring seals contained within the valve. If

a ketone is used as a cleaning agent, make sure to limit the exposure
time to no more than five minutes. Use shop air to ensure all residual
solvent has evaporated.

Orifice Cleaning
WARNING - Explosion Hazards
This procedure involves handling explosive mixtures. Ensure
venting is adequate and fuel is diluted in order to prevent explosion.
Serious injury may result if cleaning is performed while valve is
pressurized. Depressurize fuel system prior to valve cleaning.

WARNING - Health Hazard
Use Latex or other appropriate hand protection when cleaning or
disassembling valve.
The XVG/eXVG can be cleaned while it is on the turbine engine, as long
as the valve OUTLET is accessible.
Procedure 4.2.1
To clean the orifice, follow these steps:
a) Depressurize the fuel system.
b) Secure the fuel system.
c) Remove the engine igniter circuit breaker.
d) Remove the valve OUTLET fuel line.
e) Remove the orifice plate using Precision Engine Controls
Corporation special tool; P/N 5002994-001 for the XVG or P/N
5003948-001 for the eXVG, as shown in Figure 4-1 or Figure 4-2,
respectively.
f) Remove the orifice o-ring seal.
Note. Remove the orifice slowly to ensure the orifice seal and o-
rings are not damaged. Contact Precision Engine Controls
Corporation for special tool P/N 5002994-001 for the XVG
or P/N 5003948-001 for the eXVG to assist with this step.

Figure 4-1. XVG Orifice Plate Removal

Figure 4-2. eXVG Orifice Plate Removal

g) Clean away dirt and contaminants using the solvents
recommended at the beginning of Section 4.2. Ensure that the
orifice plate is clean and dry. See Figure 4-3 for a photo of the
XVG orifice plate. See Figure 4-4 for a photo of the eXVG orifice
plate
h) Inspect the orifice seal and o-ring for nicks, scrapes and damage.
If the orifice seal is damaged, contact Precision Engine Controls
Corporation for the orifice seal replacement kit; P/N 5003261-001
or -002. If the o-ring seal only is damaged, contact Precision
Engine Controls Corporation for o-ring; P/N M83248/1-034
(XVG).or P/N M83248/2-037 (eXVG).
i) Install the o-ring seal. Lubricate, as necessary, using an o-ring
lubricant, such as Parker O-Lube.
j) Install the orifice plate slowly using Precision Engine Controls
Corporation special tool; P/N 5002994-001 for the XVG or P/N
5003948-001 for the eXVG.
k) Torque the orifice plate to 8 to 10 ft-lbs.
l) Reconnect the OUTLET fuel line. Torque the flange bolts to 550-
700 in-lb.


Figure 4-3. XVG Orifice Plate

Figure 4-4. eXVG Orifice Plate

Flow Tube Cleaning
To clean the flow tube, follow these steps:
WARNING
Do NOT score the outer diameter of the flow tube. This could cause
an external fuel leak.
Procedure 4.2.2
a) Perform steps a) through g) of Procedure 4.2.1.
b) Using a soft bristle brush and solvents recommended at the
beginning of Section 4.2, gently clean the inside of the flow tube.
Clean any visible contaminants on the visible outer diameter.
c) Dry the tube inside of the flow tube using a soft towel or shop air.
d) Repeat steps 4.2.1 g) through l).

4.3 Calibration
Re-calibration in the field is not generally recommended or feasible
because flow calibration procedures require special equipment not
normally available in the field. Return the XVG/eXVG to the factory for re-
calibration if adjustments are necessary. Contact Precision Engine
Controls Corporation for Return Material Authorization (RMA) before
shipping the valve back to the factory.

4.4 Refurbishment
Contact PECC for details about refurbishment options for the XVG/eXVG.


5 TROUBLESHOOTING THE XVG/eXVG
This section aids maintenance technicians in troubleshooting and
isolating malfunctions in the XVG/eXVG. You can isolate most faults by
using the XView Communications Software. Refer to the software user
manual for fault monitoring and uploading instructions. (Contact PECC
regarding the XView User Manual.)
The XVG/eXVG contains highly reliable components and is thoroughly
tested prior to delivery. However, failures may develop over periods of
continuous service. Personnel performing fault analysis should be
thoroughly acquainted with the physical and electrical configurations as
described in Section 2: Understanding the XVG/eXVG and Section 3:
Operating the XVG/eXVG of this manual.
Resolve problems noted during operation or maintenance as soon as
possible. The cause of many problems can often be traced by using the
block diagram shown in Section 2.
WARNING
Operating the valve while it is in a malfunctioning condition may
cause serious injury or equipment damage.

5.1 Electrical Troubleshooting
If an electrical circuit failure is suspected, measure the interface circuit
impedance to determine which circuits (if any) have failed. Table 5-1 lists
expected circuit impedance values with no power connected to the valve.
If the impedance is not within the expected range, the most likely cause is
a damaged valve circuit. In such a case, return the valve to Precision
Engine Controls Corporation for repair or replacement. Contact Precision
Engine Controls Corporation for Return Material Authorization (RMA)
before shipping the valve back to the factory.
Table 5-2 lists the common failures that can be expected when the valve
is first installed. These failures are usually caused by wiring or power
supply problems.
CH. 5: TROUBLESHOOTING THE XVG/eXVG 63

Table 5-3 lists some common failures that can be expected after
equipment has been installed. These failures are usually due to power
supply problems or failures within the valve. Use the XView
Communications software to determine if there are any failures inside the
valve. Refer to Section 5.3 for information regarding these faults.

Function Wire Color Terminal # Impedance Value
Demand Input 0 Brown
Green
1
2
16.3 to 17.0 K
Analog Output 0 Yellow
Black
13
14
110 to 130 K
Analog Output 1 White
Grey
15
16
High Impedance
110 to 130 K
Solenoid Power Orange
Red
19
20
High Impedance
> 1.0 M
Electronics Power Violet
Blue
21
22
High Impedance
> 200 K
Discrete Input 0
(option)
WHT/VIO
WHT/BLK/VIO
23
24
> 10 K
Fault Alarm Output 0 WHT/ORN
WHT/BLK/ORN
31
32
> 200 K
Table 5-1. XVG/eXVG Expected Circuit Impedance
5.2 Retrieving The Fault File
First establish communication with the XVG/eXVG via the serial RS232
interface. Use the XView software to upload the fault file from the
XVG/eXVG. Only electronics power to the unit is required to upload the
fault file. Contact Precision Engine Controls Corporation to request a copy
of the XView software. See the XView manual for additional details about
uploading the fault file.
5.3 Fault Diagnosis
The XVG/eXVG continually monitors system operation parameters. If one
or more parameters are out of range for the prescribed time limit, the
valve registers a fault and shuts down. Table 5-4 lists the faults.
Pressure Faults
A pressure fault indicates a pressure sensor failure or an external system
problem. Check the fault and investigate the source of the over- or under-
pressure condition. In the case of a sensor malfunction, return the valve to
Precision Engine Controls Corporation for repair or replacement. Contact

Precision Engine Controls Corporation for Return Material Authorization
(RMA) before shipping the valve back to the factory.
Gas Temperature Faults
A gas temperature fault indicates either a temperature sensor failure or an
external system problem. Check the fuel temperature and adjust
accordingly. Continued operation beyond valve operating range is not
recommended. In the case of a sensor malfunction, return the valve to
Precision Engine Controls Corporation for repair or replacement. Contact
Precision Engine Controls Corporation for Return Material Authorization
(RMA) before shipping the valve back to the factory.
Tracking Error Fault
A tracking error indicates friction buildup in the XVG/eXVG mechanical
system. Debris around the orifice or flow tube could be the cause. Clean
the orifice and flow tube to correct this fault. Refer to Section 4:
Maintaining the XVG/eXVG for instruction on how to properly clean the
flow tube and orifice.
The tracking error fault will only enunciate when feedback is 0.025 inches
greater than demand.

Symptom Probable Causes Corrective Action
No valve feedback Electrical wires not connected
No or low 24 VDC power
Incorrect Output Set-Up
Ensure wires connected to terminal 13, 14, 21, 22
Ensure 24 VDC across terminal 21 and 22
Ensure proper A/O Channel set-up
Valve does not track fuel
Demand
Solenoid wires not connected
Solenoid wires reversed
No or low 24 VDC power level
Incorrect Set-Up

No fuel Demand
Ensure wires connected to terminal 19 and 20
Ensure solenoid power and return connected.
Ensure valve is in desired operating mode
Verify that Demand signal format being used
matches setting shown in the PDN
Verify that the inlet pressure is at least 20 psid
greater than the outlet pressure
Ensure wires connected to terminal 1, 2 and that
Demand > minimum value
Valve does not hold
consistent position-
oscillates or dithers
Varying fuel Demand signal
Improper grounding
Ensure stable fuel Demand at the valve
Ensure shields connected per Fig. 1-20
Valve closed feedback
>4.1 mA
Flow tube seal fouled
Improper grounding
Non-conforming SAE flange
Remove orifice and clean debris
Ensure shields connected per Fig. 1-20
Ensure pipe flange is flush mounted
Valve leaks when closed Flow tube seal fouled
Valve installed backwards
Ensure flow direction matches FLOW arrow
RS232 Interface
Inoperative

Incorrect wiring
COM1 not connected
Ensure connected to terminal 39, 40, 41
Check laptop/PC com port
Table 5-2. XVG/eXVG Initial Installation Troubleshooting Chart

Symptom Probable Causes Corrective Action
No position feedback No or low 24 VDC power
Self protective shutdown
Upload Fault File- check for faults. Take action on
any faults found.
Valve does not track fuel
Demand
No fuel Demand
Self protective shutdown
Ensure wires connected to terminal 1, 2 and
Demand > minimum
Upload Fault File- check for faults. Take action on
any faults found.
Valve Leaks when closed

Flow tube seal fouled
Seal damaged
Remove and replace seal
Table 5-3. XVG/eXVG In-Service Troubleshooting Chart

WARNING
The user must ensure proper 24 VDC electronics power levels,
because the XVG/eXVG will NOT produce a fault signal if the 24 VDC
electronics input power does not meet specifications. The 24 VDC
power is converted to 15V and 3.3V within the XVG/eXVG for use
with the internal components. A fault signal will only be triggered if
the 15V or 3.3V power levels are out of their respective ranges.
Critical Faults
The following are considered critical system faults because they may be
indications of major problems with the valve.
3.3 V
15V
Tracking error
LVDT sensor
Pressure sensor (inlet or outlet)
Setup checksum
Temperature sensor (gas or electronics)
Watchdog

Contact Precision Engine Controls Corporation for assistance with
troubleshooting if any of these faults are encountered. The valve may
need to be returned to Precision Engine Controls Corporation for repair or
replacement. Contact Precision Engine Controls Corporation for Return
Material Authorization (RMA) before shipping the valve back to the
factory.

Fault Description Fault # Limit Set Time Fault Action
3.3V low 1 2.97 40 ms Shutdown
3.3 V high 2 3.63 40 ms Shutdown
Tracking 10 Pos. 0.025in. over
Demand
1 sec Shutdown
Gas Temp. low 21 20 C 1 sec Warning
Gas Temp. high 22 130 C 1 sec Warning
Gas Temp. shutdown 23 140 C 10 sec Shutdown
Inlet Pressure low 41 5.0 psia 100 ms Shutdown
Inlet Pressure high 42 520 psia 100 ms Shutdown
Outlet Pressure low 51 5.0 psia 100 ms Shutdown
Outlet Pressure high 52 520 psia 100 ms Shutdown
LVDT A+B low 61 0.01 40 ms Shutdown
LVDT A+B high 62 0.04 40 ms Shutdown
LVDT AB low 63 0.04 40 ms Shutdown
LVDT AB high 64 0.04 40 ms Shutdown
LVDT pos limit 65 0.2625in. 40 ms Shutdown
Setup checksum 70 n/a 0 ms Shutdown
Flow setup 80 n/a 0 ms Warning
Solenoid Current 90 Factory-configurable n/a Warning
Inlet overpressure 101 515 psia (eXVG)
450 psia (XVG)
100 ms Warning
Outlet overpressure 102 515 psia (eXVG)
450 psia (XVG)
100 ms Warning
+15V low 110 13.5V 40 ms Shutdown
+15V high 111 16.5V 40 ms Shutdown
15V low 120 16.5V 40 ms Shutdown
15V high 121 13.5V 40 ms Shutdown
Elec. Ambient Temp. low 130 50 C 1 sec Shutdown
Elec. Ambient Temp. high 131 125 C 1 sec Shutdown
Watchdog 150 n/a 5 ms Shutdown
Table 5-4. System Health Parameters and Limits

INTENTIONALLY BLANK


APPENDIX A: DECOMMISSIONING & DISPOSAL
This section contains recommended XVG/eXVG 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.

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

Disconnect the 4 power wires, whether part of the integral wire
harness or connected to terminals, from the system power
supplies or batteries.
Disconnect the 9 or 11 signal wires, whether part of the integral
wire harness or connected to terminals, from the system circuitry.

Disposal
Follow local environmental codes in regards to disposal of electronic
components, specifically all electrolytic capacitors.
Decommissioned units may also be returned to Precision Engine Controls
Corporation for disposal in most cases. Contact the factory for details and
return authorization before shipping decommissioned units.
APPENDIX A: DECOMMISIONING & DISPOSAL 71

INTENTIONALLY BLANK


User Manual: XVG / eXVG Series Gas Fuel Metering Valve

Diunggah oleh

Informasi Dokumen

Deskripsi Asli:

Judul Asli

Hak Cipta

Format Tersedia

Bagikan dokumen Ini

Bagikan atau Tanam Dokumen

Opsi Berbagi

Apakah menurut Anda dokumen ini bermanfaat?

Apakah konten ini tidak pantas?

Hak Cipta:

Format Tersedia

User Manual: XVG / eXVG Series Gas Fuel Metering Valve

Diunggah oleh

Hak Cipta:

Format Tersedia

User Manual

XVG / eXVG Series

o-ring seals contained within the valve. If

Anda mungkin juga menyukai