INSTALLATION AND OPERATION MANUAL FOR TECJET 52 GAS REGULATI Caterpillar


Chapter 2. Installation

Usage:



Introduction

Be careful when unpacking the TecJet 52. Check the assembly for signs of damage, such as bent or dented coverts, scratches, and loose or broken parts. Be especially careful not to rest the TecJet 52 on the valve position pointer or on the actuator electrical connectors. notify the shipper and Woodward if damage is found.

If the TecJet 52 is to be painted, appropriate means must be used to mask the following items/areas:

* All identification and warning labels
* Main electrical connector
* Junction between the valve shaft and the valve housing (this is a dynamic junction next to the valve position pointer)

Mounting

TecJet 52 orientation and mounting must be designed to reduce the possibility of fuel contamination. Orientation of the valve should be with the actuator +15/-90° relative to horizontal with the sensor module skyward. The axis of the valve bore can be +90/-15° relative to horizontal, with +90° representing he outlet of the valve pointing skyward. Installations with a bore axis orientation in the +15 to +90° range must incorporate means to prevent the buildup of moisture or other liquids in the fuel train. The valve has an arrow indicating flow direction cast into the outside of the valve housing. Washers should be placed between the valve body and any fasteners used. Give consideration to the strength of the mounting plate in order to support the 17.2 kg (38 lb) weight of the TecJet 52, Refer to the outline drawing in Figure 1-1 for dimensions and details relative to the valve inlet flange and outlet flange.

For on-engine applications, a suitable bracket must be constructed to brace the valve mounting feet to a secure structure on the engine. See the outline drawing (Figure 1-1b) for the valve mounting feet hole and hole-location details. This mounting configuration should ensure that moment loads are not applied either through installation or thermal stress that could cause the valve to bind and lose functionality.

The inlet and outlet piping of the TecJet 52 must be in accordance with ANSI/ISA-S75.02 to ensure the flow metering accuracy specified elsewhere in this manual. However, an inlet piping length as short as 6 diameters and an outlet piping length as short as 2 diameters can typically be used with a negligible loss in valve metering accuracy.

Electrical Connections

TecJet 52 is electrically connected to the control system by the main connector shown in Figure 1-1. The mating connector should be torqued per the value indicated in Figure 1-1. The following mating connectors are compatible with the TecJet 52 control.


Figure 2-1. Mating Connector

Shielded Wiring

Shielded wiring is generally not required. The use of cable with individually shielded-twisted pairs is only required where indicated by the control wiring diagrams (Figure 2-1). However, some users may elect to run shielded wires for some I/O signals. Cable shields must be terminated as indicated in the control wiring diagram using the installation notes described below. DO NOT attempt to directly ground the shield at both ends since an undesired ground loop condition may occur. The TecJet 52 CAN shield connection pin is grounded through a high frequency capacitor (not directly grounded) and must be grounded in the wiring harness.

Installation Notes

* Wires exposed beyond the shield should be as short as possible, not exceeding 50 mm (2 inches).
* The shield termination wire (or drain wire) should be kept as short as possible, not exceeding 50 mm (2 inches), and where possible the diameter should be maximized.
* Installations with severe electromagnetic interference (EMI) may require additional shielding precautions. Contact Woodward for more information.

Failure to provide shielding can produce future conditions which are difficult to diagnose. Proper shielding, when provided, at the time of installation is recommended to assure satisfactory operation of the product.

Earth Ground

Ground Lug = Earth Ground

In order to ensure CE compliance, the connection to the earth ground needs to meet the following requirements. First, the connection must be less than 183 cm (6 ft) in length. Second, the wire that is used must be at least 3.3 mm2 (12 AWG) in size.


Figure 2-1. TecJet 52 Wiring Diagram

Supply Voltage

W = Power-In (+)

Z = Power-In (-)

The supply voltage during normal operation must be 18 to 32 V, measured at the TecJet 52 connector. Steady state input current can reach 1.0 A, and transient input current may reach up to 4 A. The recommended power supply cable size is at least 1.3 mm2 or 16 AWG. The power supply wiring must be fused outside of the valve. The recommended fuse is a 6 A slow blow fuse.

Recommended maximum wire length from power source to TecJet 52 based on a 24 V Power Supply: 2 51 m (167 ft) using 16 AWG (1.3mm stranded wire.

Keyswitch Input

F = Keyswitch

The keyswitch input is used to switch the TecJet 52 in and out of the run state. A high signal (connected to AUX. Power Out) will allow the valve to operated in a normal mode, and a low signal (connected to supply [-] or open connection) will force the valve to minimum position (if possible) and then into a low power state. When the keyswitch input goes low, the valve will disable the driver circuitry after the software has gone through a shutdown procedure.

PWM Input

K = PWM input (+)

L = PWM input (-)

The PMW input is configurable as the mass flow demand. The PMW input is designed for use with a push-type driver.


Figure 2-2. TecJet 52 PMW Wiring

CAN ID Inputs

H = CAN ID 1

G = CAN ID 2

J = Discreet/RS232 Common

The CAN ID inputs are used to select which CAN identifiers will be used on the CANbus. With no programming tools, the customer can select from the four pre-programmed CAN IDs thorough a hard-wired code in the engine harness. This is especially important where more than one TecJet 52 is used on an engine. If one TecJet 52 valve is replaced with another, the new valve will read the correct ID number from the engine harness connector. See the table below for the code definition. Note that the CAN ID is to be tied high, it should be connected to the Aux. power Input pin (pin C or D)

CAN Termination

P = Termination resistor

Q = Termination resistor

The internal termination resistor (124 Ohms) is used to terminate the CANbus. According to the CAN specification, every CANbus must be terminated at both ends of the bus. If a TecJet 52 valve is connected to the far end of the bus, this termination resistor can be used. If termination is needed, connect a link between pins P an Q. This link should be as short as possible. If no termination resistor is needed, leave pins P and Q unconnected.

CAN In

R = CAN high in

S = CAN low in

V = CAN Ground (do not connect unless CAN source is isolated - See fig. 2.2)

Pins R and S are the CAN communication wires. Make sure that the correct cable is used for connection to the CAN terminals (SAE J1939/11). CAN is non-isolated, and no wiring is to exceed 30 m in length.

Voltage Level: 5V

Isolation: None

Type: The TecJet 52 supports CAN 2.0B

Baud Rate: Configurable from 250 K to 1 Meg


Figure 2-3. TecJet 52 CAN Wiring for Isolated/Non-isolated Systems

CAN Out

T = CAN high out

U = CAN low out

The CAN output pins are connected to the CAN input pins internally. They are provided for linking more than one TecJet 52 to the CANbus without the need for junction boxes or doubled terminations to connector pins. For example, the CANbus from the control may be connected to the input pins, and the output pins are connected to the second TecJet 52 input pins.

CAN Ground

V = CAN ground

Pin V is the CAN ground connection for the CAN communication wires.

CAN Shield

X = CAN shield

The CAN shield can be used to terminate the shield of the CAN wiring. Internally, this pin is connected to the TecJet 52 chassis through a capacitor.

4-20 mA Analog Input

A = 4-20 mA Analog Input (+)

B = 4-20 mA Analog Input (-)

The 4-20 mA Analog Input is configurable as the mass flow demand input.

Status Output

E = Status Output

J = Discrete/RS-232 Common

The status output indicates whether the TecJet 52 valve is operating correctly. It will be "on" when the valve is operating normally and "off" when any warnings or errors are active. The Status Output electrical circuit is a low-side switch with the return current going to input power minus. It will be actively driven to Battery (-) when "on" and pulled to battery (+) through a resistor when "off". The output load must be connected to the Status Output pin and to the Aux Power Out pin of the actuator. If the load is below 500 mA, the load can be driven directly from the output. It is possible to drive a relay if more current is needed for the load.

If it is necessary to use an independent power supply instead of the AUX Power Out, then a protective fuse must be provided and the negative connection of the independent power supply must be tied to the actuator negative power input pin.

The maximum voltage when the switch is in the Off" state is 40 Vdc. The output is current protected and turns off if driven above 500 mA. If the short is removed, the output automatically returns to normal operation.

Output Type: Low-Side Discrete Output Driver

Drive Current: 500 mA max

Max. Voltage: 42 Vdc

RS-232 Serial Communication Service Port

M = Serial TX

M = Serial RX

J = Discrete/RS-232 Common

The RS-232 service port is used to configure, calibrate and trouble shoot the TecJet 52. The TecJet Service Tool can be downloaded from the internet at www.woodward.com/software. The RS-232 wiring must meet the requirements in the EIA RS-232 Standard document. An external TTL to RS-232 converter (Woodward PN 1249-1039) is necessary to make communications possible with the Woodward TecJet Service Tool. The converter must be located a maximum of 1 meter from the TecJet 52. A connectivity kit can be purchased from Woodward to accomplish this. Further instructions for using this connectivity kit are provided in Chapter 5.

Isolation: None

Baud Rate: 38.4 Kbaud

Auxiliary Power Output

C = Aux. Power Out

D = Aux. Power Out

The Auxiliary power output pins are designed as a convenient way to wire any of the inputs that require a pull-up to battery, such as keyswitch and the CAN ID pins. This is also a good way to supply power through a load to the Status Output. Using the AUX. Power Output for these functions is highly recommended for the best EMI performance. Please note that using the AUX. Power Out in the keyswitch circuit will protect the circuitry from harmful surges in power.

Caterpillar Information System:

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