5-1-111
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SERVICE BULLETIN
NOTICE:
The Type of Change and Recommended Compliance specified reflects Solar’s best judgment regarding the
Service Bulletin. All questions should be directed to your Solar Field Service Representative. Solar, Saturn,
Centaur, Taurus, Mercury, Mars, Titan, SoLoNOx, and Turbotronic are trademarks of Solar Turbines Incorporated.
Cat and Caterpillar are trademarks of Caterpillar Inc. Specifications subject to change without notice.
NUMBER:
5.1/111
ISSUED:
January 1980
REVISED:
PRODUCT:
Centaur
MODEL(S):
Specifics:
SUBJECT: RECUPERATOR ACCELERATION TEMPERATURE
CONTROL (RATC, Z139) P/N 946734C92 - CALIBRATION
AND CHECKOUT PROCEDURES
Type of Change:
Product Information
Recommended
Compliance:
Information
Purpose:
To provide a procedure for installation, checkout and calibration of the Recuperator Acceleration
Temperature Control (Z139). This bulletin is being published as a supplement to the Operation and
Maintenance Instructions manual.
GENERAL INFORMATION:
MONITOR OPERATION DESCRIPTION:
The Recuperator Accelerator Temperature Control (RATC) is a solid state device mounted in the
control console. It’s function is to control the engine’s acceleration schedule during start to limit
the temperature differential across the recuperator.
The RATC senses inlet air temperature (T1), combustor inlet temperature (T2C), and power turbine
inlet (T5) to T2C differential temperature (
T = T5 - T2C). Based on these parameters, the RATC
biases the 0 to 5 V dc analog signal from the T5 temperature monitor to the Main Fuel Actuator
Control (MFAC) during starts only (Between 0 and 90 percent Ngp).
SERVICE BULLETIN
Page 1 of 11
NUMBER: 5.1/111
The control phases on start are:
Phase 1 - Phase 1 is the acceleration and temperature control between 0 and 60 percent Ngp. From
crank initiation to lightoff, the Main Fuel Actuator (which controls the throttle valve) is controlled
by the Ramp Generator (Z149). When the engine lights off, the differential temperature (
T) sensed
by the RATC increases. AT 225 F, the
T switch transfers control of the Main Fuel Actuator from
the Ramp Generator to the Main Fuel Actuator Control (MFAC), which in turn is controlled by the
RATC monitor (Z139). At lightoff the temperature is controlled by low speed (
T) topping with
the controlling parameter being T2C and
T with T1 bias.
When the engine lights off with a cold recuperator (low T2C) the RATC limits the
T to a low
value ( Figure 1). (
T = 260 F at T2C = 80 F, when T1 = 80 F). As the recuperator warms up
and T2C increases, the
T limit is increased to a proportionately higher value. (For example,
T
= 300 F at T2C = 110 F, and
T = 600 F at T2C = 300 F when Tl = 80 F.)
T is also allowed
to increase as Tl decreases. (For example,
T = 300 F at T2C = 110 F, when Tl = 80 F; but
T
= 400 F at same T2C of 110 F when T1 decreases to -40 F.)
As T2C increases,
T is allowed to increase to a value that will allow T5 to increase to 975
F.
From this point through 60 percent Ngp, the temperature is controlled by low speed T5 topping,
which is limited to 975 F.
Phase 2 - At 60 percent Ngp, temperature control transfers to medium speed topping, which allows
T5 to increase to a higher value. To prevent overtemperature shutdown from a rapid increase in the
fuel schedule, a ramp voltage is introduced which initiates a smooth transition to the higher topping
setting. From 60 to 90 percent speed, Ngp topping is controlled by T5 with a T1 bias. The T1 bias
varies the T5 topping limit from 850 F at -40 F T1 to 1150 F at 80 F T1.
Phase 3 - At 90 percent Ngp, the ramp voltage initiates a smooth transition to the normal high speed
T5 topping limit of 1150
F.
INPUTS TO THE RATC:
1.
T5, power turbine inlet temperature: 0 to 5 volts dc analog from engine temperature
monitor Z182.
2.
T2C, combustor air inlet temperature: from TC339-1 thermocouple.
3.
T, differential temperature T5 - T2C: from thermocouple TC382 - TC339-2.
4.
T1, air inlet temperature: from R339 resistance temperature detector RTD.
5.
60 percent Ngp switch: from gas producer speed monitor Z183.
6.
90 percent Ngp switch: from gas producer speed monitor Z183.
7.
24 volts dc: from control battery.
Page 2 of 11
SERVICE BULLETIN
NUMBER: 5.1/111
Figure 1
Recuperator Acceleration/Temperature Schedule
SERVICE BULLETIN
Page 3 of 11
NUMBER: 5.1/111
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OUTPUTS FROM THE RATC:
1.
Low speed topping (0 to 60 percent Ngp): limits
T to150 to 640 F as a function of T1
and T2C, or to975 F as a function of T5.
2.
Medium speed topping (60 to 90 percent Ngp): limits T5 to 850 to 1150 F as a function
of Tl.
3.
High speed topping (above 90 percent Ngp): limits T5 to ll50 F.
4.
T switch: signals engine lightoff at 225 F
T.
Seven potentiometer (pots) arc provided under the RATC (Z139) data plate for adjust-
ment of temperature limits and switch setpoints ( Figure 2).
TEST EQUIPMENT REQUIRED:
1.
Audio frequency signal generator.
2.
Digital frequency counter (optional).
3.
Voltmeter (0 to 10 V dc).
4.
Three (3) low impedance millivolt power supplies (0 to 25 mV) such as Minimite or
battery operated power supply.
5.
Digital temperature indicator (K-couple).*
6.
Digital millivolt meter (0 to 25 mV).*
7.
Switch (DPDT) (optional).
8.
Resistors or decade box (110-ohm ± 1 percent and 84 ohm ± 1 percent).
9.
Test Lamp (24 V dc).
* May be combined in one instrument.
SYSTEM CONNECTION CHECK (REQUIRED AT INITIAL STARTUP ONLY):
1.
Verify that fuel and start gas and dc electrical power are off.
2.
Disconnect electrical connectors from Z139 (RATC), Z144 (MFAC), Z182 T5), and
Z153 (Npt).
Page 4 of 11
SERVICE BULLETIN
NUMBER: 5.1/111
Figure 2
RAT Potentiometer
3.
Verify that fotlowing jumpers are removed.
Table 1
CKT
TB
to
TB
CKT
41
103-11
103-14
889
42
103-10
103-13
888
895
315-12
305-9
898
896
315-11
305-10
897
224A
101-19
101-17
224
225A
101-20
101-18
225
44
101-5
Remove and
attach to blank
TB 101-6
4.
Verify the following connections using an ohmmeter.
Table 2
Connector
Pin
to
Pin
Connector
Continuity
P139
U
T
P139
Yes
P139
T
S
P139
90 to 120
Ohms
P139
E
F
P139
0 to 40
Ohms
SERVICE BULLETIN
Page 5 of 11
NUMBER: 5.1/111
Table 2
(Cont’d)
Connector
Pin
to
Pin
Connector
Continuity
P139
P
R
P139
0 to 40
Ohms
P139
Y
N
P139
Yes
P139
K
W
P139
No
P139
L
Y
P139
No
P139
L
X
P139
Yes
P139
K
W
P139
Yes
P139
W
G
P139
Yes
P139
Y
Y
P139
Yes
5.
Verify that no continuity exists between all RATC box connector pins and box case
(ground).
6.
Turn dc control power on and verify the following connections, using an ohmmeter.
NOTE
Terminal board (TB) numbers, wire numbers, and Test Equipment Hookup
instruction number 8 shown in brackets are for later model units. Check
these numbers against your control system and cross out improper num-
bers.
a.
Energize K263-2 relay by installing temporary jumper between wire No. 13
(TB207-9) and wire No. 57 (TB210-12).
Table 3
Control
Pin
to
Pin
Control
Continuity
P139
Y
V
P139
Yes
b.
Energize K251-3 relay by installing temporary jumper between wire No. 13
(TB207-9) and wire No. 27 (TB207-14) TB210-16 .
Page 6 of 11
SERVICE BULLETIN
NUMBER: 5.1/111
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Table 4
Control
Pin
to
Pin
Control
Continuity
P139
X
G
P144
Yes
c.
Energize K230 relay by installing temporary jumper between wire No. 13
(TB207-9) and wire No. 33 (TB210-9) T1-8.
Table 5
Control
Pin
to
Pin
Control
Continuity
P144
H
Z
P144
No
d.
Disconnect wire No. 895 (red) from K351-A2 relay contact. Energize K351 relay
by installing temporary jumper between wire No. 13 (TB207-9) and wire No. 27
(TB207-14) TB210-16 .
7.
Turn dc control power off.
8.
Connect electrical connectors to Z139, Z144, Z182, and Z153.
TEST EQUIPMENT HOOKUP (FIGURE 3):
SPECIAL PRECAUTIONS SHALL BE TAKEN IN EXPLOSION PROOF
(EP) AREAS TO ENSURE REQUIREMENTS ARE MET BEFORE OPEN-
ING EP BOXES.
1.
T5 Input: Disconnect input leads from T5 thermocouple at TB203-18 (wire No. 898
Al-red-minus) and TB203-19 (wire No. 897 CR-yel-plus). Connect output leads from
first millivolt power supply POSITIVE (red) to TB203-19 and NEGATIVE (black) to
TB203-18. Label power supply T5.
2.
T2C Input: Disconnect input leads from T2C thermocouple at TB203-16 (wire No. (813)
[864] yellow) and TB203-15 (wire No. (814) [865] red). Connect output leads from
second millivolt power supply POSITIVE (red) to TB203-16 and NEGATIVE (black)
to TB203-15. Label power supply T2C.
3.
T Input: Disconnect input wires from
T thermocouples at TB203-12 (No. 884)
TB203-13 (No. 885). Connect third millivolt power supply POSITIVE (red) lead
to TB203-12 and NEGATIVE (black) lead to TB203-13. Label power supply
T.
Connect leads from digital voltmeter POSITIVE to TB203-12 (884) and NEGATIVE
to TB203-13 (885).
SERVICE BULLETIN
Page 7 of 11
NUMBER: 5.1/111
Figure 3
Test Equipment Connections
4.
Ngp Input: Disconnect input leads from gas producer magnetic pickup from TB201-4
(black, 22) and TB201-5 (white, 23). Connect output leads from signal generator to
TB201-4 and TB201-5.
5.
Voltmeter Output: Select voltmeter 10 volts dc range and connect leads POSITIVE (red)
to TB202-5 and NEGATIVE (black) to TB202-4.
6.
Connect AL-CR leads from temperature indicator to common of DPDT switch.
Observing polarity, connect leads from N.O. connection on switch, AL (NEGATIVE -
red) to TB203-15 and CR (POSITIVE - yellow) to TB203-16. Label (NO) normally
open position T2C. Observing polarity, connect leads from (NC) connection on switch,
AL (NEGATIVE - red) to TB203-19 and CR (POSITIVE - yellow) to TB203-18. Label
N.C. position T5.
7.
Disconnect wire No, 875 from TB203-8, wire No. 876 from TB203-9, and wire No. 878
from TB203-10. Connect 110-ohm resistor between TB203-8 and TB203-9, and install
a jumper wire between TB203-9 and TB203-10.
8.
(Connect the 24 V test lamp to wire No. 799 (TB102-9) POSITIVE, and wire No. 2
(TB207-1) NEGATIVE.)
[Connect the 24 V test lamp to wire no. 96A (+) from RATC at (TB102-10) [TB203-22],
and to wire No. 2 (TB207-I).]
Page 8 of 11
SERVICE BULLETIN
NUMBER: 5.1/111
NOTE
Check these instructions against your control system and cross out im-
proper instruction.
9.
Disconnect wire No. 93 (TB206-13) [TB208-21] that connects with K210-3D to disarm
the ramp generator.
TESTING AND CALIBRATION:
TEST AND CALIBRATION SHALL BE PERFORMED WITH ENGINE
SHUTDOWN.
NOTE
RAT unit should have power applied and be stabilized for a minimum of two
hours before calibration.
Set
T switch setpoint:
1.
Turn dc power on.
2.
Remove top cover from RAT box, exposing seven potentiometer ( figure 2).
3.
Adjust speed setting pot R155 fully clockwise.
4.
Set Ngp = 20 to 50 percent.
5.
Set T2C = 110 F.
6.
Set T5 = 400 F.
7.
Increase
T and verify that
T switch trips (test light extinguishes) at 5.14 mV (225
F).
8.
Adjust R34 in RATC (Z139) and repeat step 6 until switch trips at 5.14 mV.
9.
Decrease
T and verify that
T switch retransfers (1ight illuminates) below 2.99 mV
(131 F) with greater than one second delay on dropout.
Set high speed T5 topping limit (Ngp greater than 90 percent):
1.
Inputs T2C and
T are the same as in switch setpoint above.
2.
Set Ngp = 95 percent.
SERVICE BULLETIN
Page 9 of 11
NUMBER: 5.1/111
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3.
Set T5 = 1150
F.
4.
Adjust pot No. 2 in the MFAC (Z144) for 3.5 V dc output to fuel actuator (L344).
5.
Verify T5 analog voltage to the RATC (No. 42 POSITIVE, T6-2, and No. 41 NEGATIVE
T6-1) is equal to T5 analog voltage to the MFAC (No. 888 POSITIVE, TB103-13; and
No. 889 NEGATIVE, TB103-14). Tolerance is 50 mV. If greater, replace RATC.
Set low speed topping limit (Ngp lower than 60 percent):
Set position and slope of
T topping limit (recuperator warmup schedule with 110 ohm resistor
for RTD, or T1 = 80 F).
1.
Set
T topping with low T2C.
a.
Set Ngp = 20 to 50 percent
b.
Set T2C = 110 F
c.
Set T5 = 400 F
d.
Set
T = 6.8 mV
e.
Adjust R6 in RATC (Z139) to obtain 3.5 V dc output to fuel actuator (L344).
2.
Set
T topping with high T2C:
a.
Set T2C = 300 F.
b.
Set T5 = 400 F.
c.
Set
T = 13.5 mV.
d.
Adjust R47 in RATC box to obtain 3.5 V dc output to fuel actuator (L344).
e.
Repeat steps 1 and 2 until no further change is observed.
3.
Verify
T topping offset:
a.
Replace 110 ohm resistor installed in step 7 under Test Equipment Hookup with
the 84 ohm resistor. (T1 = -40 F)
b.
Set T2C = 110 F.
c.
Set T’5 = 400 F.
d.
Set
T = 9.0 mV.
e.
Verify output to fuel actuator (L344) is 3.5 ± 0.4 V dc. If voltage is not within
specifications, replace RATC (Z139) box.
4.
Set T5 topping limit:
a.
Replace 84-ohm resistor installed in step 3 above with the 110 ohm resistor.
b.
Set Ngp = 20 to 50%.
Page 10 of 11
SERVICE BULLETIN
NUMBER: 5.1/111
c.
Set T2C = 400 F.
d.
Set
T = 7.9 mV.
e.
Set T5 = 975 F.
f.
Adjust R13 in RATC (Z139) box to obtain 1.5 V dc output to fuel actuator (L344).
Set T5 ramp voltage:
1.
Set inputs same as in steps 4 above.
2.
Slowly increase setting of Ngp until 60% speed switch transfers.
3.
Verify that output to fuel actuator (L344) increases slowly (approximately two seconds)
to maximum voltage with no decrease.
4.
Adjust R26 in RATC and repeat steps 2 and 3 until repeat operation is observed.
Set medium speed T5 topping limit (Ngp between 60 and 90%):
1.
Set T5 limit with high T1 (80
F).
a.
Set Ngp = 65 to 80%.
b.
Set T2C = 400 F.
c.
Set
T = 7.9 mV.
d.
Set T5 = 1150
F.
e.
Adjust R4 in RATC to obtain 3.5 V dc output to fuel actuator (L344).
2.
Set T5 limit wtth low T1 (-40 F).
a.
Replace the 110 ohm resistor installed in step 7 of Test Equipment Hookup with
the 84 ohm resistor,
b.
Make all settings as in step 1 above.
c.
Set T5 = 850 F.
d.
Adjust R10 in RATC to obtain 3.5 V dc output to fuel actuator (L344).
e.
Repeat steps 1 and 2 until repeat operation is observed.
Restore all systems to normal.
SERVICE BULLETIN
Page 11 of 11
NUMBER: 5.1/111
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