agv10 manual

7/28/2019 Agv10 Manual

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Version 3.0

II 2 G 0344, 0036 Class I, Div 1, 2, Group D: T4EEx d IIA T4KEMA 03ATEX2551

ISO 9001:2000 CERTIFIED

AGV10 FUEL CONTROL VALVE

Installation and Operation Manual


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PREFACE

This manual provides instruction and maintenance information for the AGV10 Fuel Control Valve.

It is highly recommended that the user read this manual in its entirety before commencingoperations. It is the policy of Continental Controls Corporation that it is neither our intention norour obligation, to instruct others on how to design or implement engine control systems.Continental Controls Corporation will not assume responsibility for engine controls not designedor installed by our authorized representatives.

This manual is intended to help the end user install and operate the AGV10 Fuel Control Valve inthe manner in which they were intended and in a way to minimize risk of injury to personnel ordamage to engine or equipment.

Do NOT attempt to operate, maintain, or repair the fuel control valve until the contents of thisdocument have been read and are thoroughly understood.

Every attempt has been made to provide sufficient information in this manual for the properoperation and maintenance of the AGV10 Fuel Control Valve.

All information contained within shall be considered proprietary information and its release tounauthorized personnel is strictly prohibited.

If additional information is required, please contact:

Continental Controls Corporation

8845 Rehco Road

San Diego, CA, 92121

(858) 453-9880


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SAFETY WARNING!The Continental Controls Fuel Control Valves are normally used with natural gas. NaturalGas and Air, when combined together, the mixture becomes very combustible. Whencontained within an enclosure, such as a gas turbine engine or its exhaust system canexplode in a violent manner when ignited. It is necessary to always use extreme cautionwhen working with any fuel system.

Controls for Gas Engines should always be designed to provide redundant fuel shut downs.Towards this goal, the Fuel Control Valve plays an important part in the safety of the wholesystem. The AGV10 is not the primary control to shut down the engine.

The AGV10 Fuel Control Valve is NOT a shutoff valve. Shutoff valves should be used inaddition to the Fuel Control Valve. The fuel system should be designed in such a way that:

1. No single failure of a component wil l cause the fuel system to admit

fuel to the engine when the engine has been shutdown.

2. No single failure can result in grossly over-fueling the engine whenattempting to start.

Failure to follow the above rules may lead to possibly serious damage toequipment or injury to personnel!

Failure to follow the above rules may lead to possibly serious damage to equipment or topersonnel.

The AGV10 Fuel Control Valve is to meter fuel gas only and should not be used as a mainfuel system shutoff valve. A separate fuel shutoff valve must be installed UPSTREAM of theAGV10. The fuel shutoff valve should provide for the venting of pressure from the upstreamside of the AGV10 before an engine start sequence is initiated. If no venting is provided, thefuel system must be such that no gas is trapped downstream of the AGV10. It is thecustomers responsibility to insure that purge times are completed and the igniter of theturbine is turned on before fuel pressure is allowed to reach the AGV10.

Before installing the AGV10 Fuel Control Valve, check as to whether or not the valvecontains an embedded acceleration schedule. The AGV10-XX A is the designation that thevalve that does have an embedded acceleration schedules. This valve will only allow anappropriate level of gas to the turbine based upon the compressor discharge pressure (PCDor CDP). A non-acceleration schedule valve will allow a level of gas proportional to level ofthe fuel demand signal supplied to the valve.

When the acceleration schedule is to be turned off, one of the enclosed warning tags shallbe affixed to the valve in such a way as to cover the part number on the valve. The


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technician disabling the acceleration schedule will need to call Continental Controls with thenumber on the tag he has affixed to the valve in order to get the equation code for the valvebefore the schedule may be turned off.

WARNING THIS VALVE ACCELERATION

SCHEUDLE HASS BEEN DISABLED!

This valve is only compatible with PLCs and withacceleration schedule


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TRANSLATIONS OF CAUTION AND WARNING

1. WARNING:DO NOT DISCONNECT EQUIPMENT UNLESS POWERHAS BEEN SWITCHED OFF OR AREA IS KNOWN TO BE NON-

HAZARDOUSI: ATTENZIONE: APRE CIRCUITO PRIMA DI TOGLIERECOPERCHIO L'L'IL

G: ACHTUNG: OFFENER KREISLAUF VOR HERAUSNEHMEN VONDECKE

2. WARNING:DO NOT DISCONNECT EQUIPMENT UNLESS POWERHAS BEEN SWITCHED OFF OR AREA IS KNOWN TO BE NON-HAZARDOUS

I: L'AVVERTIMENTO: NON DISINSERISCE L'APPARECCHIATURAA MENO CHE IL POTERE STATO DISINSERITO O L'AREA

SAPUTA PER ESSERE NON RISCHIOSOG: WARNEN: SCHALTEN Sie GERTE NICHT AB ES SEI DENNNETZSCHALTER AB ODER GEBIET IST GEWUSST, SEI ZU SEIN

3. VALVE MUST BE CONNECTED TO ELECTRICAL CONDUIT INORDER TO COMPLY WITH CLASS I, DIV. I REQUIREMENTS

I: LE VALVOLE COLLEGATE CON UN CONDOTTO SONOCONFORME A DELLE CLASSI I, DIV. I REQUISITO

G: VENTILE HABEN MIT EINER LEITING SICH AN KLASSE I, DIVVERBUNDEN ANHLT I BEDINGUNG

4. KEEP COVER TIGHT WHILE CIRCUIT IS CLOSED

I: TENERE I COPERCHI STRETTI MENTRE CIRCUITO SONO VIVO

G: BEHALTEN Sie DECKEN DICHT, WHREND KREISLAUFLEBEND IST

5. CLASS I , DIV I REQUIRES HEAT RESISTANT RATED MIN. 105 CWIRE, CABLE GLAND, AND CONDUIT SEAL

I: DELLE CLASSI I, DIV. I , Il CALORE CAVO RESISTENTE, LAGLANDOLA DI CAVO, IL SIGILLO DI CONDOTTO, & I FILIMETALLICI DI CONDOTTO SARANNO USATI

G: KLASSE I, DIV VERBUNDEN ANHLT I WRME WISERSTANDSFHIGES KABEL, KABEL DRSE, LEITUNG, LEITUNGABDICHTUNG, & LEITUNG, DIE DRBENUTZT WERDEN WARDEN

CAUTION

VALVE MUST BE CONNECTED TO

ELECTRICAL CONDUIT IN ORDER TO COMPLY

WITH CLASS 1, DIV. 1 REQUIREMENTS

WARNING:

DO NOT DISCONNECT EQUIPMENTUNLESS POWER HAS BEEN SWITCHED

OFF OR AREA IS KNOWN TO BENON-HAZARDOUS

WARNING:

SUBSTITUTION O F COMPONENTSMAY IMPAIR SUITABILITY FOR

CLASS 1, DIV. 1

CAUTION:

OPEN CIRCUIT BEFOREREMOVING COVER

KEEP COVER TIGHT WHILE

CIRCUIT IS CLOSED

CLASS 1, DIV. 1 REQUIRES HEAT RESISTANTRATED MIN. 105C WIRE, CABLE GLAND,

AND CONDUIT SEAL,


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Table of Contents

PREFACE I

SAFETY WARNING! I I

TRANSLATIONS OF CAUTION AND WARNING IV

ADDENDUM TO INSTALLATI ON OF AGV10 FUEL CONTROL VALVE 8

AGV10 INSTALLATION DOS AND DONTS 9

VALVE PRE-INSPECTI ON 10

LIST OF MATERIALS NEEDED FOR CORRECT INSTALLATION 12

GENERAL CONSIDERATIONS 12

GENERAL CONSIDERATIONS 13

INSTALLATION LOCATIONS 13

STANDARD INSTALLATION: 15STANDARD INSTALLATION WITH FILTER: 16

STANDARD NON-VENT INSTALLATION: 16

STANDARD NON-VENT INSTALLAT ION WITH FILTER: 17

ELECTRICAL CONNECTIONS 18

CONDUIT CONNECTION 18HAZARDOUSAREA REQUIREMENTS 18POWER SUPPLY 19


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CONNECTING THE CONTROL SIGNALS TO / FROM THE AGV10 20

CONNECTING TO THE NON-ISOLATED 4 TO 20 MA VALVE INPUT(DEMAND SIGNAL) 20

CONNECTING TO A NON-ISOLATED 4 TO 20 MA VALVE OUTPUT (FLOWFEEDBACK SIGNAL) 21

INSTALLATION WITH MFAC BOXES 22

REMOTE COMMUNICATIONS WITH THE AGV10 FUEL CONTROL VALVE23

THEORY OF OPERATIONS 24

OVERVIEW 24PROPORTIONAL CONTROL 24CONTROL DEMANDOFFSET 25FLOW ADJUSTMENT OFFSET 25

ALTITUDE ADJUSTMENT 25DEMANDGAIN 25

TRANSDUCER OFFSET 26GAUGE RANGE 26ACCELERATIONGAIN 26ACCELERATION (Y)OFFSET 27ACCELERATION (X)OFFSET 27

TYPICAL CALIBRATION VALUES 27AGV10WITHOUT ACCELERATIONCONTROL 27AGV10WITH ACCELERATIONCONTROL 28

MAINTENANCE 30

MAINTENANCE OF THE AGV10FUEL CONTROL VALVE 30PREVENTATIVE MAINTENANCE 30CORRECTIVE MAINTENANCE 31REGULATOR &FILTER CLEANING OR REPLACEMENT 31VALVE POPPET ASSEMBLY REMOVAL 33REMOVAL OF FOREIGN DEBRIS FROM POPPET ASSEMBLY 35REPLACEMENT OFTRANSDUCERS 36


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VALVE INTERFACE SOFTWARE 38

LOADING INTERFACETERMINAL SOFTWARE 38ESTABLISHING COMMUNICATION WITH VALVE 39

TECHNICAL SPECIFICATIONS & OPTIONS 44

AGV10FUEL CONTROL VALVE SPECIFICATIONS 44VALVE MATERIAL 45

PRODUCT WARRANTY 46

APPENDIX I 47

ENVELOPE DRAWING 47

APPENDIX II 51

BASIC SERVICE DRAWING 51

APPENDIX II 55

ELECTRICAL DRAWING 55

DIGITAL POWER SUPPLY 55


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INSTALLATION

Addendum to installation of AGV10 Fuel Control Valve

When installing the AGV10 Fuel Control Valve, the possibility exists that welding slag ortubing cuttings, or other debris may foul the Poppet assembly if allowed to enter theAGV10. If this occurs, the AGV10 may not function properly, due to the Poppet assemblybeing improperly seated. To this effect Continental Controls recommends that one (1) oftwo (2) types of safeties be installed to monitor the amount of fuel present in the engineduring light off. The installation of these items provides a redundant safety measure,

ensuring that there is no single point failure of the fuel system.

1. An installed pressure switches on the fuel manifold to detect over-fueling duringignition. The switch would be electrically connected in series with the Shut-offValve solenoids. If the switch detects an unsafe condition, the fuel supply wouldbe cut-off and the AGV10 would cease providing fuel.

2. Monitoring of the flow feedback signal (4 to 20mA) from the AGV10. When anunsafe condition during ignition is detected, the monitoring device (i.e. PLC) wouldabort the start in progress, close the fuel solenoids and disable the igniter.

When installing the AGV10 Fuel Control Valve in a Class I Div 1 Group Denvironment; heat resistant rating of 105C min Cable, Cable Gland, Conduit Seal,and Conduit Wires must be used at the NPT threaded opening. Installation of allelectrical Equipment will be in compliance with the National Electric Code (NEC).


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AGV10 Installation Dos and Donts

1. Do not install the valve in such a manner that will trap gas pressure within the

downstream side of the valve.

2. Always provide an adequate supply pressure for the application.

3. Where the gas is extremely sour, dirty, or has liquid suspension, install a separate

pilot gas supply with an external filter. An air purge option is also available for the

AGV10.

4. Supply the valve with +24Vdc w/ 1 amp at the valve. Using small gauge wire may

cause a large voltage drop resulting in an inadequate power supply.

5. Do not create ground loops.

6. The flow signal on the AGV10 is NOT loop powered.

7. Never install valve wires within the same conduit as items such as igniter wires or

large solenoid wires.

8. If installing a Loader style valve on a Solar Centaur engine, install a vent to allow

the relay logic to perform the shut off valve verification.

9. Never paint the valve.

10. Never replace the valve with that of a different configuration.

11. Do not install the valve in such a manner where condensate may build up insidethe electronics housing.


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0

Valve Pre-Inspection

The gas fuel-metering valve should be inspected immediately after unpacking. Check forany damage that may have been incurred during shipping. If there are any questionsregarding the physical integrity of the valve, call Continental Controls immediately.

NOTE: If possible, keep the original valves shipping container. If future transportation orstorage of the valve is necessary, this container will provide the optimum protection.

Ensure that the AGV10 received matches the model no. And configuration of the fuelvalve to the packing list and if possible, to the purchase order. The top plate of theAGV10 contains information pertinent to that particular valve, i.e. embedded accelerationschedule.

The AGV10 is the designation of all small, configured valves from Continental Controls.The dash number (i.e. AGV10-1) denotes the engine that the valve has been configuredand calibrated for. Some examples are shown below:

-1 Saturn Engine Solar Turbines Inc-3 Centaur Engine Solar Turbines Inc-6 Centaur H Engine Solar Turbines Inc

FUEL CONTROL VALVECAUTION

VALVE MUST B E CONNECTED T O

ELECTRICAL CONDUIT IN ORDER TO COMPLY

WITH CLASS I, DIV 1 REQUIREMENTS

WARNING:

DO NOT DISCONNECT EQUIPMENT

UNLESS POWER HAS BEEN SWITCHEDOFF OR AREA IS KNOWN TO BE

NON-HAZARDOUS

WARNING:

SUBSTITUTION OF COMPONENTS

MAY IMPAIR SUITABILITY FOR

CLASS I, DIV 2

HAZARDOUSLOCATION RATINGCLASS I, DIV 1,GROUP D, T4(-40C TO 85C)

CAUTION:

OPEN CIRCUIT BEFORE

REMOVING COVER

KEEP COVER TIGHT WHILE

CIRCUIT IS CLOSED

II 2 G

CLASS I, DIV 1 REQUIRES HEAT RESISTANT

RATED MIN. 105C WIRE, CABLE GLAND,

AND CONDUIT S EALUS PATENT # 5,146,941

TEMP: -40-20

C TO 85C

500 PSIG (35 BAR)

C TO 85C (ATEX)

MAX PRESSURE (PS):

NOTIFY BODY NO. 0036

0344

Different configurations for the valve are available for other engine types manufactured bymost other engine manufacturers.


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1

The optional features included in the valve are denoted by a single letter designation. Alist of optional features is shown below:

A Embedded acceleration schedule

C Control signal is 0 to 50mA. (Control Input is 4 to 20 mA unlessdenoted otherwise.)

D Control Signal is 0 to 200 mA

E The valves electrical connections are by conduit entry (with seal)and therefore the valve is explosion-proof and approved for usewithin Class I, Div I hazardous areas as defined by the appropriateelectrical code.

F 2 ANSI 300lbs, 8-bolt flange

M RS-485 serial communications

N The valve is NACE compliant for use in sour gas service

P The valve is configured for use with an external filter on the pilot gasinlet

S 2 SAE 4-bolt (series 61) flange

T Extended temperature service

If the valve information matches correctly, then it is the appropriate fuel-metering valve foryour engine application.


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2

List of Materials needed for correct Installation

The following is just a list of materials needed:

1. AGV10 Fuel Control Valve

2. Flange kit (optional) - contains two, 304L stainless steel block flanges (orequivalent), mounting bolts and o-rings. Pipe thread sizes are available in 1.5and 2.

3. Pilot Gas Filter (optional)

4. Mounting plate (optional)

5. Pipe wrench(s)

6. Assorted SAE wrenches

7. Wire cutters/strippers


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3

General Considerations

When considering where to place the AGV10 Fuel Control Valve it is recommended thatseveral issues be kept in mind.

The valve should be located away from any extreme sources of heat.Operating ambient temperature is 40 to +85C [-20C to 85C forATEX]. Temperatures higher than this will require special precautionsfrom the manufacturer. However, if the temperature of the fuel gas is

agv10 manual

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