MAN B&W Page 1 of 8 Calibration and Function test Ident. No.: 0743484-8 Calibration and Function Test Procedure for FIVA, ELFI and ELVA Valves This document is valid for existing engine types on order as of the date of this document: Production Specification Engine types: April 2015 0743484-8.4 All ME engine types. Info No: 314179 Structure No: 21-3010 Replaces: Scope and Field of Application This Production Specification deals with the calibration and function test of FIVA, ELFI and ELVA valves. Picture of FIVA valve Document history Date Designer Checked AC Revision change Revision 2007-07-31 JVS JSC 2011-09-26 SVO JSC Z3 Fig 1. section 4 and section 7 updated 2 2012-07-31 SVO JSC Z3 Documentation updated to include ELFI valve 3 2015-04-21 SVO JSC Z3 ELVA valve added 4 0 Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany MAN Diesel & Turbo Registered with the Danish Commerce and Companies Agency under CVR-no. 31611792 (referred to as “MAN Diesel & Turbo”). This document is the property of MAN Diesel & Turbo and is to be treated as confidential by the party to whom it has been submitted by MAN Diesel & Turbo, and may not be disclosed to any third party without the specific prior written permission of MAN Diesel & Turbo. This document may be a translation of an original English language document. In case of any discrepancy between the original English language document and this translation, it is always the original English language document which shall prevail. The original English language document may have been replaced by a later version, in which case only such later version shall be valid. Teglholmsgade 41, 2450 Copenhagen SV, Denmark Phone +45 33 85 11 00 E-mail mandieselturbo-cph@mandieselturbo.com Web www.mandieselturbo.com Production Specification 0743484-8.4 Page 2 of 8 Contents Changes in this revision: 1. Introduction�����������������������������������������������������������������������������3 ELVA valve added. 2. References �����������������������������������������������������������������������������3 3. Calibration of FIVA and ELFI valves���������������������������������������4 4. Extreme position check ���������������������������������������������������������5 5. Check of default position on loss of control signal to pilot valve �������������������������������������������������������������������������������6 6. Measuring output signal from position sensor with calibration rod�������������������������������������������������������������������������7 7. Function test for ELVA valve���������������������������������������������������8 7.1. Test safe position of ELVA 8 7.2. Function test 8 Date 2015-04-21 Section 7 is new. Designer Checked AC Revision change Revision SVO JSC Z3 ELVA valve added 4 Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743484-8. Calibration and Function Test Procedure for FIVA, ELFI and ELVA Valves Production Specification 0743484-8.4 Page 3 of 8 ELFI FIVA Position sensor Calibration potentiometer Marked “Z” Position sensor Calibration potentiometer Marked “Z” • Z • Z Pilot valve Pilot valve Main Spool Spool Plug Screw Plug Screw Figure 1: FIVA and ELFI valve. 1. Introduction Before a FIVA or ELFI valve is sent into service it must be calibrated and function tested: Calibration. Checking output signal from the position sensor in both extreme positions. Check of default position on loss of control signal to pilot valve. The FIVA valve main spool defaults to the “exhaust valve fully open” position when the pilot valve positioning signal is removed. The ELFI valve main spool defaults to the fully open to tank position when the pilot valve positioning signal is removed. Measuring af output signal from position sensor when Calibration Rod is mounted. Before an ELVA valve is send into service it must be function tested: Test safe position. Function test. 2. References MAN B&W Production Specification: No 0743505-4; Marks and Stamps on FIVA, ELFI and ELVA Valves. Date 2015-04-21 Designer Checked AC Revision change Revision SVO JSC Z3 ELVA valve added 4 Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743484-8. Calibration and Function Test Procedure for FIVA, ELFI and ELVA Valves Production Specification 0743484-8.4 Page 4 of 8 3. Calibration of FIVA and ELFI valves The FIVA or ELFI valve is mounted in the hydraulic test rig. The position sensor is connected to an instrument where the output signal in mA from the position sensor is displayed. The positioning input to the pilot valve is increased until the flow through the FIVA or ELFI valve corresponds to: FIVA I: V = 15L/min ± 0.2 l/min. T = 42ºC ± 1ºC. P = 250 bar ± 1 bar. FIVA II: V = 30L/min ± 0.2 l/min. T = 42ºC ± 1ºC. P = 250 bar ± 1 bar. ELFI: V = 20L/min +/- 0,2 L/min. T = 42°C. +/- 1 gr. P = 250 bar +/- 1 bar. The ampere meter used for calibration must have a precision better than 0.5% of 20 mA. The feed back sensor must then be adjusted to give the mA value stated on the drawing. The adjustment is done by tuning the potentiometer screw marked “Z” on the feed back sensor. Warning! Do not attempt to adjust other potentiometers than the one marked “Z” as it may damage the sensor. Date 2015-04-21 Designer Checked AC Revision change Revision SVO JSC Z3 ELVA valve added 4 Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743484-8. Calibration and Function Test Procedure for FIVA, ELFI and ELVA Valves Production Specification 0743484-8.4 Page 5 of 8 4. Extreme position check Change the positioning signal to the pilot valve corresponding to “Fuel injection fully open”position. Check that the output signal from the positioning sensor is within the 4-20 mA range. FIVA Figure 2: Example for FIVA - Fuel port fully open. FIVA: Change the positioning signal to the pilot valve corresponding to “Exhaust valve fully open” position, see figure 3. ELFI: Change the positioning signal to to the pilot valve corresponding to »fully open between fuel injection and tank« position, see figure 4. Check that the output signal from the positioning sensor is within the 4-20 mA range. Date 2015-04-21 Designer Checked AC Revision change Revision SVO JSC Z3 ELVA valve added 4 Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743484-8. Calibration and Function Test Procedure for FIVA, ELFI and ELVA Valves Production Specification 0743484-8.4 Page 6 of 8 FIVA ELFI Figure 3: Exhaust port fully open default position. Figure 4: Oil inlet fully open to tank. 5. Check of default position on loss of control signal to pilot valve Remove the input signal to the pilot valve. Check that the main spool moves to the default position, see figure 3 and figure 4. The output from the positioning sensor must still be within the 4-20 mA range. Date 2015-04-21 Designer Checked AC Revision change Revision SVO JSC Z3 ELVA valve added 4 Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743484-8. Calibration and Function Test Procedure for FIVA, ELFI and ELVA Valves Production Specification 0743484-8.4 Page 7 of 8 6. Measuring output signal from position sensor with calibration rod This measurement gives a reference signal from the positioning sensor when the main spool is placed in a well defined position. This operation should be carried out without oil pressure on the FIVA or ELFI valve. FIVA ELFI Calibration Rod Calibration Rod Figure 5: Calibration rod mounted. Remove the plug screw and mount the calibration rod. Turn the calibration rod carefully by hand until the calibration rod is seated correctly against the FIVA valve housing. Measure the output from positioning sensor. Stamp the output value on the nameplate of the FIVA valve. Remove the calibration rod and remount the plug screw. Date 2015-04-21 Designer Checked AC Revision change Revision SVO JSC Z3 ELVA valve added 4 Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743484-8. Calibration and Function Test Procedure for FIVA, ELFI and ELVA Valves Production Specification 0743484-8.4 Page 8 of 8 7. Function test for ELVA valve The ELVA valve is mounted in the hydraulic test rig. P = min. 225 bar. 7.1. Test safe position of ELVA When valve is pressurized with min. 225 bar in the P port flow should go to the C port. It means at failing electric connection to pilot valve the exhaust valve will open 7.2. Function test When the pilot valve is energized / activated the ELVA valve must connect the C port to the T port. Activate the pilot valve 10 times in order to verify that the slide moves freely in the housing. Note! Date 2015-04-21 The ELVA valve is a fast On/off valve. Operating it with high flow will create large pressure peaks in the connected system. To prevent this we advise to limit the flow to the valve during testing by restricting the P-port flow with an orifice or a drilling in the mounting flange with max diameter Ø2 mm. Designer Checked AC Revision change Revision SVO JSC Z3 ELVA valve added 4 Copyright © 2015 MAN Diesel & Turbo, branch of MAN Diesel & Turbo SE, Germany 0743484-8. Calibration and Function Test Procedure for FIVA, ELFI and ELVA Valves