INSTALLATION AND OPERATION MANUAL FOR TECJET 52 GAS REGULATI Caterpillar

Overview

The Service Tool software is used to configure, setup, and troubleshoot the TecJet^TM 52 control. This chapter describes the installation and use of the TecJet Service Tool and provides detailed instructions for configuring and setting up the TecJet 52 control for customer-specific applications.

Description

The TecJet 52 Service Tool software resides on a PC (personal computer) and communicates to the TecJet 52 control via RS-232 connection. An external TTL to RS-232 transceiver (Woodward P/N 1249-1039) is needed to make possible communications with the Woodward TecJet Service Tool. This works best if it is wired into the harness within 18 inches (1 meter max) of the TecJet 52 control.

A communication harness kit can also be purchased from Woodward (one each of Woodward P/N 1249-1120 and 1249-1039). See Figure 5-1 for the communication harness connections.

The communication harness kit is a service port adaptor and is not intended to remain in the engine wiring harness during normal operation (only during engine setup). To use the adaptor, a 9-pin straight-through serial cable is needed between the harness transceiver RS-232 port and the PC. This serial cable must include ALL conductors. If it is limited to only pins 2, 3 and 5, it will not function correctly with the adaptor.

Installation

The TecJet 52 Service Tool is available at www.woodward.com/software. Select software product "TecJet Service Tool". Follow the installation instructions given on that page.

System Requirements

The following hardware is required to work with the TecJet 52 control:

* PC-compatible laptop or desktop computer

* Microsoft Windows® XP, 2000, NT 4.0 Service Pack 6a, Me, or 98

* 300 MHz Pentium® CPU

* 64 MB or RAM

* Minimum 800 by 600 pixel screen with 256 colors

* Serial Port

* Serial Extension Cable

* Communication/data link harness.

What to do next

After the software is installed, install the communication harness and connect a straight-through 9-pin serial communications cable between the converter RS-232 port and an unused serial port on your computer. Power must be applied to the TecJet 52 control for the Service Tool to connect.

Run the Service Tool program and, when prompted, select an available com port. This will connect the Service Tool to the TecJet 52 control. Once connected to the control, the Overview screen (Figure 5-2) will open and populate with current values and the status bar will display 'connected'. The TecJet 52 Demand Source and the active Control Status messages are also displayed in an area common to all screens.

Service Tool Help

Online Service Tool help is available and included with the installation of the Service Tool product. Help can be accessed from the Service Tool 'Help" menu located on the main screen.

Service the Security

There are no password security levels provided by the TecJet Service Tool.

Troubleshooting the Driver

The Service Tool has six (6) screens for troubleshooting drivers driver parameters:

* Overview (Figure 5-2)

* Troubleshooting (Figure 5-3)

* Warnings (Figure 5-4)

* Errors (Figure 5-5)

* Configuration (Figure 5-6)

* Identification (Figure 5-7)

Screen Navigation

Service Tool screens can be selected for viewing by clicking the various tabs provided on the main and edit configuration screens.

Overview Screen

The Overview screen is the default screen that opens when connecting the TecJet Service Tool to the TecJet 52 control. The Overview screen displays TecJet 52 flow parameters and the valve position. The status bar, common to all screens, displays communication, warning and error status. The triangular warning symbol turns yellow when a warning is active. The round error symbol turns red when an error is active.

Figure 5-2. Overview Screen

Flow Demand- Displayed value of the flow demand input, in normal liters/second.

Gas Flow- Displayed value of the gas flow, in liters/second, at FGT and FGP.

Gas Density- Displayed value of the gas density, in grams/cubic meter, at FGT and FGP.

Fuel Gas Temperature (FGT)- Displayed value of the inlet fuel gas temperature, in degrees Celsius.

Fuel Gas Pressure (FGP)- Displayed value of the inlet fuel gas pressure, in millibar absolute.

Displayed value of the valve differential pressure, in millibar differential.

Valve Position- Displayed value of the valve position, in radians.

Troubleshooting Screen

Select the Troubleshooting tab to view general TecJet 52 control parameters. This screen dynamically populates based on the TecJet 52 configuration. If a function is not programmed, then it will not appear. The analog configuration is shown here.

Figure 5-3. Troubleshooting Screen

Electronics Temperature- Displayed value of the electronics temperature sensor, in degrees Celsius.

Coil Current- Displayed value of estimated actuator coil current, in amperes.

Input Supply- Displayed value of the input power, in volts.

Running Hours- Displayed value of the running hours.

Reset Running Hours- To reset the running hours to zero, click the 'Reset Running Hours' button.

Keyswitch Input Status- Displayed status of the keyswitch input. Value is active or inactive.

PWM Frequency (PWM Demand Source Configuration Only)- Displayed value of the PWM input frequency, in hertz.

PWM Duty Cycle- Displayed value of the PWM input duty cycle, in %.

Analog Input Current (Analog Demand Source Configuration Only)- Displayed value of the analog input, in milliamps.

CAN Status- Displayed value of the CAN status (e.g., error passive, stuff error, etc.)

Reset CAN Status- To clear the displayed CAN status, click the 'Reset CAN Status' button.

CAN ID- Displayed value of the CAN identification number. Value is 1, 2, 3 or 4.

CAN Rx Error Count- Displayed value of the CAN receiver error counter.

CAN Tx Error Count- Displayed value of the CAN transmit error counter.

Warnings Screen

Select the Warnings tab to view TecJet 52 active or previously active warning conditions. Warnings indicate a problem has occurred that needs attention but the valve attempts continued operation. This screen dynamically populates based on the TecJet 52 configuration. If a function is not programmed, then it will not appear. A Reset Warnings button is provided to clear inactive warnings.

Figure 5-4. Warnings Screen

Errors Screen

Select the errors tab to view active TecJet 52 error conditions. Errors indicate a serious problem has occurred and the valve is not able to operate. This screen dynamically populates based on the TecJet 52 configuration. If a function is not programmed, then it will not appear.

Figure 5-5. Errors Screen

Shutdown- Indicates the valve is closed or attempting to close due to a detected error.

Internal Fault- Indicates an internal fault has occurred that prevents normal operation of the valve.

Sensor High- Indicates the Delta Pressure value has exceeded the delta pressure sensor's electrical high limit threshold.

Sensor Low- Indicates the Delta Pressure value has exceeded the delta pressure sensor's electrical low limit threshold.

Position Sensor High- Indicates the Valve Position value has exceeded the position sensor's electrical high limit threshold.

Position Sensor Low- Indicates the Valve Position value has exceeded the position sensor's electrical low limit threshold.

Position Error- Indicates the position feedback is not following the position demand. Position Error detection logic is designed to account for normal actuator response times to prevent unwarranted position error indications during transient conditions.

J1939 Address Claim Failed (EGS-02 Demand Source Configuartion Only)- Indicates the control cannot claim the Source Address. Another control with a higher priority is claiming the address.

Configuration Screen

Select the Configuration tab to view the TecJet 52 configuration. This screen dynamically populates based on the existing TecJet 52 configuration. If a function is not programmed, then it will not appear. The configuration settings are grouped into 4 or 5 sub-screens. Select a sub-tab to view the configuration settings for that group.

Figure 5-6. Configuration Screen

Identification Screen

Select the Identification tab to view the TecJet 52 identification information.

Figure 5-7. Identification Screen

Software Part Number Displayed software part number and revision letter.

Serial Number Displayed TecJet 52 valve serial number.

Hardware Part Number Displayed TecJet 52 valve part number and revision letter.

Configuring the Driver

The Service Tool has six (6) screens for editing the driver configuration:

* Edit TecJet Configuration, Demand Source (Figure 5-8)

* Edit TecJet Configuration, General (Figure 5-9)

* Edit TecJet Configuration, Flow (Figure 5-10a, 10b, 10c)

* Edit TecJet Configuration, Failed Sensor Defaults (Figure 5-11)

* Edit TecJet Configuration, Filters (Figure 5-12)

* Edit TecJet Configuration, CAN (Figure 5-13a, 13b)

Edit Configuration

To change the TecJet 52 configuration, click the Edit Configuration button on the Configuration screen.

This opens an Edit TecJet Configuration screen, (e.g., Figure 5-8), to permit driver configuration setting changes. The configuration settings are provided in a common area of the Edit TecJet Configuration screen and on several tabbed screens.

Edit TecJet Configuration, Demand Source

The Demand Source configuration appears in a common area of the Edit TecJet Configuration screen.

To configure the Demand Source, click the radio button adjacent to the desired demand source from those listed. This selection dynamically populates the remaining tabbed configuration screens. If a function is not applicable to the configured demand source, then it will not appear.

Figure 5-8. Edit TecJet Configuration, Demand Source

Jenbacher CAN- Sets the Demand Source for Jenbacher CAN input signal.

Analog 4-20- Sets the Demand Source for an Analog 4-20 mA input signal.

PWM- Sets the Demand Source for a PWM input signal.

EGS-01- Sets the Demand Source for a Woodward EGS-01 control input signal.

GECM- Sets the Demand Source for a GECM input signal.

EGS-02- Sets the Demand Source for a Woodward EGS-02 control input signal.

Edit TecJet Configuration, General

This is an edit screen for general control configuration settings. To change a value, highlight the value and type the desired value. The status bar displays the valid adjustable range for the highlighted value.

Figure 5-9. Edit TecJet Configuration, General

K

Sets the fuel ratio of specific heats when used by the flow algorithm when values are not received on the CAN bus or when CAN is not configured. Adjustable Range: 1.0 to 2.0.

Density (p)

Sets the fuel gas normal density, in grams/cubic meter at flowing temperature (FGT) and pressure (FGP), used by the flow algorithm when values are not received on the CAN bus or when CAN is not configured. Adjustable Range: 400.0 to 2600.0 g/m3.

Low Temperature- Sets the temperature, in °C, which triggers a Fuel Gas Temperature Low warning indication. Adjustable range: -40 to 25° C

High Temperature- Sets the temperature, in °C, which triggers a Fuel Gas Temperature High warning indication. Adjustable range: 25 to 90° C

Low Pressure- Sets the pressure, in millibar, which triggers a Fuel Gas Pressure Low warning indication. Adjustable range: 0 to 1600 millibar

High Pressure- Sets the pressure, in millibar, which triggers a Fuel Gas Pressure High warning indication. Adjustable range: 0 to 1600 millibar

Low
- Sets the differential pressure, in millibar, which triggers a
Low warning indication. Adjustable range: 0 to 1600 millibar

High
- Sets the pressure, in millibar, which triggers a
High warning indication. Adjustable range: 0 to 1600 millibar

Edit TecJet Configuration, Flow

This screen provides for editing the flow configuration settings used by the control. This screen dynamically populates based the Demand Source configuration. If a parameter is not applicable for the configured demand source, then it will not appear. To change a value, highlight the value and type the desired value. The status bar displays the valid adjustable range for the highlighted value.

Figure 5-10a. Edit TecJet Configuration, Flow (CAN Demand)

CAN Flow Demand Timeout-

Sets the timeout period, in milliseconds, which triggers a CAN Flow Demand Failed warning. Adjustable Range: 10.0 to 10000.0 ms

Figure 5-10b. Edit TecJet Configuration, Flow (Analog Demand)

Analog Input Minimum- Sets the current, in milliamps, which triggers an Analog Flow Demand Low warning. Adjustable Range: 0 - 22 mA

Analog Input Maximum- Sets the current, in milliamps, which triggers an Analog Flow Demand High warning. Adjustable Range: 0 - 22 mA

Scaling- Sets the low and high values for scaling the analog demand source versus fuel flow. The current range set by the scaling/low/current and scaling/high/current settings will cause the TecJet 52 valve to deliver the corresponding fuel flow set by the scaling/low/flow and scaling/high/flow settings. Intermediate values are linear with between these low and high settings.

* Scaling, Current, Low

Sets the current, in milliamps, which corresponds to the Low Flow setting. Adjustable range: 3-22 mA

* Scaling, Current, High

Sets the current, in milliamps, which corresponds to the High Flow setting. Adjustable range: 3-22 mA

* Scaling, Flow, Low

Sets the flow, in normal liters/second, for the corresponding Low Current setting. Adjustable range: 0-2000 NI/s

* Scaling, Flow, High

Sets the flow, in normal liters/second, for the corresponding High Current setting. Adjustable range: 0-2000 NI/s

Figure 5-10c. Edit TecJet Configuration, Flow (PMW Demand)

PMW Duty Cycle Minimum- Sets the PMW duty cycle, in percent, which triggers a PMW Flow Demand Low warning. Adjustable Range: 2-50%

PMW Duty Cycle Maximum- Sets the PMW duty cycle, in percent, which triggers a PMW Flow Demand High warning. Adjustable Range: 50-98%

Scaling- Sets the low and high values for scaling the PMW demand source versus fuel flow. The duty cycle range set by the scaling/low/duty cycle and scaling/high/duty cycle settings will cause the TecJet 52 valve to deliver the corresponding fuel flow set by the scaling/low/flow and scaling/high/flow settings. Intermediate values are linear with between these low and high settings.

* Scaling, Duty Cycle, Low

Sets the PMW duty cycle, which corresponds to the Low Flow setting. Adjustable range: 5-95%

* Scaling, Duty Cycle, High

Sets the PMW duty cycle, which corresponds to the High Flow setting. Adjustable range: 5-95%

* Scaling, Flow, Low

Sets the flow, in normal liters/second, for the corresponding Low Duty Cycle setting. Adjustable range: 0-2000 NI/s

* Scaling, Flow, High

Sets the flow, in normal liters/second, for the corresponding High Duty Cycle setting. Adjustable range: 0-2000 NI/s

Edit TecJet Configuration, Failed Sensor Defaults

This screen provides for editing the Failed Sensor Default configuration settings used by the control in the event a sensor input fails. To change a value, highlight the value and type the desired value. The status bar displays the valid adjustable range for the highlighted value.

Figure 5-11. Edit TecJet Configuration, Failed Sensor Defaults

Default Temperature- Sets the temperature, in °C, the control will use to continue operation upon failure of the fuel gas temperature sensor. Adjustable range: 0 to 60° C

Default Downstream Pressure- This sets as estimated pressure, in millibar absolute, that the control will use to continue operation upon failure of the fuel gas pressure sensor.

Estimate is based on a 4-point curve of the flow demand, in normal liters/second, versus default downstream pressure, in millibar absolute. (Estimated FGP = Default Downstream Pressure +
).

* Flow Demand [1-4]

Sets the flow demand [1-4], in normal liter/second, which corresponds to the default downstream pressure setting. Adjustable Range: 0-2000 NI/s

* FGP-
[1-4]

Sets the default downstream pressure [1-4], in mbar abs for the corresponding flow demand [1-4] settings. Adjustable Range: 0-2000 mbar abs

Edit TecJet Configuration, Filters

This screen provides for editing various input signal filter configuration settings. To change a value, highlight the value and type the desired value. The status bar displays the valid adjustable range for the highlighted value. The filters are provided for system troubleshooting purposes, and should be set to 0 in normal applications.

Figure 5-12. Edit TecJet Configuration, Filters

Filter Time Constant- Sets the Delta P sensor time constant. There is a single-pole lag between the delta P sensor and the flow algorithm. Adjustable range: 0 to 5 sec

Fuel Gas Pressure Filter Time Constant- Sets the Fuel Gas Pressure sensor time constant. There is a single-pole lag between the fuel gas pressure sensor and the flow algorithm. Adjustable range: 0 to 5 sec

Fuel Gas Temperature Filter Time Constant- Sets the Fuel Gas Temperature sensor time constant. There is a single-pole lag between the fuel gas temperature sensor and the flow algorithm. Adjustable range: 0 to 5 sec

Flow Demand Filter Time Constant- Sets the Flow Demand time constant. There is a single-pole lag between the flow demand value and the flow algorithm. Adjustable range: 0 to 5 sec

Edit TecJet Configuration, CAN

This screen provides for editing CAN communication configuration settings. To select a "Default" or "User Configured" baud rate, click the radio button adjacent to each choice.

Figure 5-13a. Edit TecJet Configuration, CAN (Default)

Baud Rate, Default

Sets the baud default rate of the CAN communication in kbps. Adjustable range: 10, 50, 100, 125, 250, 500, or 1000 kbps.

Figure 5-13b. Edit TecJet Configuration, CAN (User Configured)

Baud Rate, User Configured

Provides user settings for more flexible control of the CAN parameters. This option should be used by advanced users only. The baud rate of the CAN communication is calculated from the settings as follows:

Baud Rate = 40E6 / [(BRP + 1) x (TSEG1 + TSEG2 + 1)]

Baud Rate prescaler (BRP)- Sets the baud rate prescaler in the CAN controller. Adjustable range: 0 to 255

TSEG01- Sets the Tseg1 value in the CAN controller. Tseg1 combines the PROP_SEG and PHASE_SEG1 segments of the CAN protocol. Adjustable range: 3-16

TSEG02- Sets the Tseg2 value in the CAN controller. Tseg2 defines the PHASE_SEG2 segment of the CAN protocol. Adjustable range: 2-8

Synchronization Jump Width- Determines the synchronization jump width in the CAN controller. Adjustable range: 1-4

Load Configuration Settings

To load the configuration changes to the TecJet 52 control, click the 'OK" button on the Edit TecJet Configuration screen. A loading Configuration message will appear to verify the configuration settings are being loaded to the control. The Edit TecJet Configuration screen closes after the settings are loaded.

Click the 'Cancel' button to exit the Edit TecJet Configuration screen without saving the configuration changes to the control. A message will appear asking for verification that the configuration changes are not to be saved to the control.