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26090B

RAPTOR™
Gas Regulation and Metering
Valve/Actuator System for
Caterpillar

Installation and Operation Manual

Manual 26090B
WARNING
Read this entire manual and all other publications pertaining to the work to
be performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions. Failure to follow
instructions can cause personal injury and/or property damage.

The engine, turbine, or other type of prime mover should be equipped with
an overspeed (overtemperature, or overpressure, where applicable)
shutdown device(s), that operates totally independently of the prime mover
control device(s) to protect against runaway or damage to the engine,
turbine, or other type of prime mover with possible personal injury or loss
of life should the mechanical-hydraulic governor(s) or electric control(s),
the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or
the controlled device(s) fail.

CAUTION
To prevent damage to a control system that uses an alternator or battery-
charging device, make sure the charging device is turned off before
disconnecting the battery from the system.

Electronic controls contain static-sensitive parts. Observe the following


precautions to prevent damage to these parts.
• Discharge body static before handling the control (with power to the
control turned off, contact a grounded surface and maintain contact
while handling the control).
• Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
• Do not touch the components or conductors on a printed circuit board
with your hands or with conductive devices.

IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.

CAUTION—indicates a potentially hazardous situation which, if not


avoided, could result in damage to equipment.

NOTE—provides other helpful information that does not fall under the
warning or caution categories.

Revisions—Text changes are indicated by a black line alongside the text.

Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© 2001 by Woodward Governor Company
All Rights Reserved
Manual 26090 RAPTOR Valve/Actuator System

Contents

CHAPTER 1. GENERAL INFORMATION.......................................................... 1


Introduction .............................................................................................................1
Connections to the RAPTOR Valve........................................................................1
General Installation and Operation Notes and Warnings .......................................2
CHAPTER 2. ELECTROSTATIC DISCHARGE AWARENESS............................... 3
CHAPTER 3. INSTALLATION ........................................................................ 5
Introduction .............................................................................................................5
Mounting .................................................................................................................5
Electrical Connections ............................................................................................8
Supply Voltage ................................................................................................9
Key Switch ......................................................................................................9
PWM Input ......................................................................................................9
CAN ID Inputs ...............................................................................................10
CAN Termination ..........................................................................................10
CAN 1 (in) .....................................................................................................11
CAN 2 (out) ...................................................................................................11
CAN HF Ground............................................................................................11
Diagnostics ...........................................................................................................11
Service Port ..........................................................................................................12
CHAPTER 4. DESCRIPTION OF OPERATION ................................................ 13
Power On Procedure ............................................................................................13
Mass Flow Demand Input .....................................................................................13
Specifications........................................................................................................14
Electrical Characteristics ..............................................................................14
Mechanical Characteristics ...........................................................................14
Environmental ...............................................................................................15
Flow Characteristics......................................................................................15
Regulatory Compliance.................................................................................16
CHAPTER 5. VALVE SIZING....................................................................... 17
CHAPTER 6. TROUBLESHOOTING .............................................................. 19
CHAPTER 7. MAINTENANCE ...................................................................... 27
RAPTOR Sensor Module Replacement Procedure..............................................27
CHAPTER 8. SOFTWARE UPGRADE ........................................................... 31
CHAPTER 9. APPLICABLE DOCUMENTS ..................................................... 33

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RAPTOR Valve/Actuator System Manual 26090

Illustrations and Tables

Figure 3-1a. RAPTOR Valve Outline Drawing (1000 and 2000 mm) .....................6
Figure 3-1b. RAPTOR Valve Outline Drawing (1000 and 2000 mm) .....................7
Figure 3-2. RAPTOR Valve Wiring Diagram ..........................................................8
Figure 3-3. Flashing Code Example .....................................................................12
Figure 5-1. RAPTOR Valve Sizing Diagram .........................................................18
Figure 7-1. Installing the Sensor Module ..............................................................28
Figure 7-2. Connecting the Sensor Module Ribbon Cable ...................................29

Table 6-1. Troubleshooting Guide: Normal Run Mode.........................................20


Table 6-2. Troubleshooting Guide: Non-Normal Run Mode .................................20
Table 6-3. Troubleshooting Guide: Shut-Down Codes .........................................23

ii Woodward
Manual 26090 RAPTOR Valve/Actuator System

Chapter 1.
General Information

Introduction
The RAPTOR™ product is an integrated, digitally compensated control valve
and actuator system for regulating and metering the flow of gaseous fuels. The
device is designed to accept a fuel rate demand signal. It also incorporates
feedback sensors which monitor fuel pressure and temperature, and valve
pressure differential. Based on the signal inputs, the device modulates the valve
opening to produce a physical fuel mass flow which closely matches the flow
demand level.

The device is intended to be mounted on or very close to the engine. The


dominant application of these valves is gas fueled reciprocating engines provided
with an electronic engine control system.

NOTE
Throughout the remainder of the manual, the RAPTOR valve and
actuator system will be referred to simply as the RAPTOR valve.

Connections to the RAPTOR Valve


The RAPTOR valve has the following connections to the ECM (Engine Control
Module), and the engine harness:

Earth Ground Provided through ground lug on housing.


Power Input 18–32 Vdc measured at the RAPTOR valve.
Key Switch input Contact input to switch the RAPTOR valve ON and OFF.
CAN bus Primary demand input.
PWM input Secondary demand input.
CAN ID inputs Raptor number selection for CAN bus IDs.
CAN termination Internal CAN termination resistor option.
CAN bus out Second set of CAN pins for connecting to the next CAN
device.

The RAPTOR valve has one service port for program upgrades by qualified
service personnel.

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RAPTOR Valve/Actuator System Manual 26090
General Installation and Operation Notes and
Warnings
The RAPTOR valve is suitable for use in Class I, Division 2, Group C, and D per
CSA for Canada and U.S. or non-hazardous location only.

The RAPTOR valve wiring must be in accordance with the Class I, Division 2
wiring methods and in accordance with the authority having jurisdiction.

Wiring for the RAPTOR valve power input must be suitable for at least 85 °C.

Connect ground terminal of RAPTOR valve to earth ground.

WARNING
Explosion Hazard—Do not remove covers or connect/disconnect
electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

Explosion Hazard—Substitution of components may impair


suitability for Class I, Division 2.

AVERTISSEMENT
Risque d'explosion—Ne pas enlever les couvercles, ni raccorder /
débrancher les prises électriques, sans vous en assurez auparavant
que le système a bien été mis hors tension; ou que vous vous situez
bien dans une zone non explosive.

Risque d’explosion—La substitution de composants peut rendre ce


matériel inacceptable pour les emplacements de Classe I, Division 2.

2 Woodward
Manual 26090 RAPTOR Valve/Actuator System

Chapter 2.
Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.


To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.

Follow these precautions when working with or near the control.

1. Before doing maintenance on the electronic control, discharge the static


electricity on your body to ground by touching and holding a grounded
metal object (pipes, cabinets, equipment, etc.).

2. Avoid the build-up of static electricity on your body by not wearing


clothing made of synthetic materials. Wear cotton or cotton-blend materials
as much as possible because these do not store static electric charges as
much as synthetics.

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam


cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.

4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:

• Do not touch any part of the PCB except the edges.

• Do not touch the electrical conductors, the connectors, or the


components with conductive devices or with your hands.

• When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.

CAUTION
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.

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RAPTOR Valve/Actuator System Manual 26090

4 Woodward
Manual 26090 RAPTOR Valve/Actuator System

Chapter 3.
Installation

Introduction
WARNING
The RAPTOR™ valve weighs 43 kg (94 lbs). In order to prevent injury,
some form of lifting assistance (a lifting strap is recommended)
should be used when handling the RAPTOR valve.

Be careful when unpacking the RAPTOR valve. Check the assembly for signs of
damage, such as bent or dented covers, scratches, and loose or broken parts.
Notify the shipper and Woodward if damage is found.

Mounting
The RAPTOR valve is designed to operate within a temperature range of 0 to 85
°C (32 to 185 °F) with a gaseous fuel flow temperature of 0 to 60 °C (32 to 140
°F).

The RAPTOR valve should be mounted with the electronic enclosure facing up.
It must be mounted onto a flat plate with 0.500-13 size bolts. Consideration must
be given to the strength of the mounting plate, in order to support the 43 kg (94
lbs) weight of the RAPTOR valve.

The inlet piping of the RAPTOR valve must be in accordance with ANSI/ISA-
S75.02 as required for flow metering accuracy. There are two outlet piping
solutions possible:
• Straight flow
• Tee flow

The straight flow solution is used mainly for in-line engines or engines with only
one cylinder bank.

The tee flow solution is mainly used for V engines or engines with two cylinder
banks, two mixers, and two turbos.

NOTE
Close the unused ports with appropriate blocking flanges and
gaskets (not delivered with the RAPTOR valve). Plug unused
pressure ports (P2 inlet—see outline drawing) with 0.125 NPT pipe
plug(s) if applicable.
The outlet piping solution for each RAPTOR valve is indicated on the
device nameplate.

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RAPTOR Valve/Actuator System Manual 26090

WARNING
Leak check all gaseous fuel connections. Leaking gaseous fuel can
cause explosion hazards, property damage, or loss of life.

Figure 3-1a. RAPTOR Valve Outline Drawing (1000 and 2000 mm)
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Manual 26090 RAPTOR Valve/Actuator System

Figure 3-1b. RAPTOR Valve Outline Drawing (1000 and 2000 mm)

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RAPTOR Valve/Actuator System Manual 26090
Electrical Connections
The RAPTOR valve is connected to the control system (ECM) by the main
connector. The engine harness mating connector is an Amphenol GTC06CF20-
29S(025)188.

To Previous CAN
Device

}
RAPTOR
C CAN HI IN
F CAN LO IN
N CAN HF GND
D CAN HI OUT
E CAN LO OUT
R
Jumper for CAN Termination
P

}
Resistor
To Next CAN
J SPARE
Device
H SPARE
A CAN ID1
B CAN ID2
G SPARE
S
T
PWM IN +
PWM IN - } SeeBelow
Options

M Key Switch
Battery
K Battery +
L Battery -

ECM ECM
S PWM IN + S PWM IN +
T PWM IN - T PWM IN -

return to
Battery -

L Battery -

Single-wire configuration Dual-wire configuration

Figure 3-2. RAPTOR Valve Wiring Diagram

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Manual 26090 RAPTOR Valve/Actuator System

WARNING
Explosion Hazard—Do not remove covers or connect/disconnect
electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

AVERTISSEMENT
Risque d'explosion—Ne pas enlever les couvercles, ni raccorder /
débrancher les prises électriques, sans vous en assurez auparavant
que le système a bien été mis hors tension; ou que vous vous situez
bien dans une zone non explosive.

Supply Voltage
K = Supply voltage (+)
L = Supply voltage (–)

The supply voltage during normal operation must be 18 to 32 V, measured at the


RAPTOR valve connectors. Input current is typically less than 1.0 A, but
momentary current peaks can reach 6 A. The recommended power supply cable
size is 1.3 mm² or 16 AWG. The power supply wiring must be fused outside of
the valve. A slow-blow type, 6 A fuse is recommended.

Key Switch
M = Key switch

The key switch is used to cycle power to the RAPTOR valve. A high signal
(connected to supply [+]) will turn the valve on, and a low signal (connected to
supply (–) or open connection) will turn it off. This signal provides a convenient
way to shut down the RAPTOR valve, so that a high-power (6 A) relay is not
needed at the supply voltage input. When the key switch input goes low, the
valve will switch off the internal power after the software has gone through a
shutdown procedure.

PWM Input
S = PWM input (+)
T = PWM input (–)

The PWM input is used as the secondary mass flow demand input. The scaling
used on this secondary flow demand is received from the ECM via CAN and
stored in the RAPTOR valve. It will switch to this input automatically if the
CAN link, or primary flow demand input, is lost.

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RAPTOR Valve/Actuator System Manual 26090
As shown in Figure 3-2, there are two options for connecting the PWM input to
the ECM. In the single-wire configuration, the RAPTOR PWM (–) input should
be connected to the RAPTOR Battery (–) pin.

If the RAPTOR valve has detected a shutdown failure (closing the valve if
possible), the pull-up resistance on the PWM input is opened. An ECM which
has open-circuit detection capability on its PWM driver can then detect that the
RAPTOR valve has shutdown, even if the CAN link diagnostics have been lost.

CAN ID Inputs
A = CAN ID 1
B = CAN ID 2

The CAN ID inputs are used to select which CAN identifiers will be used on the
CAN bus. With no programming tools, the customer can select from the four
pre-programmed CAN IDs through a hard-wired code in the engine harness. This
is especially important where more than one RAPTOR valve is used on an
engine. If one RAPTOR 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.

RAPTOR CAN ID CAN ID1 CAN ID2


"Raptor 1" High or Open High or Open
"Raptor 2" Low High or Open
"Raptor 3" High or Open Low
"Raptor 4" Low Low

CAN Termination
R = Termination resistor
P = Termination resistor

The internal termination resistor is used to terminate the CAN bus. According to
the CAN specification, every CAN bus must be terminated at both ends of the
bus. If a RAPTOR valve is connected to the far end of the bus, this termination
resistor can be used. If termination is needed, connect a link between pin P and
pin R. This link should be as short as possible. If no termination resistor is
needed, leave pins R and P unconnected.

WARNING
If the internal termination is used, other devices on the CAN bus may
not operate properly when the RAPTOR valve is disconnected from
the bus. An external termination resistor should be used if there are
other devices on the CAN bus that must not lose communication
when the RAPTOR valve is disconnected.

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Manual 26090 RAPTOR Valve/Actuator System
CAN 1 (in)
C = CAN high in
F = CAN low in

Pins C and F are the CAN communication wires. Make sure that the correct
cable is used for connection to the CAN terminals (SAE J1939/11).

CAN 2 (out)
D = CAN high out
E = CAN low out

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

WARNING
If a second device is connected to the CAN output pins, this device
will lose communication if the RAPTOR valve is disconnected.

CAN HF Ground
The CAN HF (High Frequency) ground can by used to terminate the shield of
the CAN wiring. Internally, this pin is connected to the RAPTOR case through a
capacitor.

Diagnostics
The RAPTOR valve, being a “smart valve”, has advanced diagnostics. There are
two ways of communicating the diagnostic codes:
• CAN link
• Diagnostic LED (visible on the cover)

WARNING
The RAPTOR valve may not return to minimum fuel for all faults. The
engine, turbine, or other type of prime mover should be equipped
with an over speed, misfire, detonation detection shutdown
device(s), that operate totally independently of the prime mover
control device(s) to protect against runaway or damage to the engine,
turbine, or other type of prime mover with possible personal injury or
loss of life should the RAPTOR system fail.

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RAPTOR Valve/Actuator System Manual 26090
The Raptor diagnostic codes are displayed on the diagnostic LED by flash codes:
• Flashing Green: Normal run
• Orange Code: Alarm—see troubleshooting guide for code descriptions
• Red Code: Shutdown—see troubleshooting guide for code descriptions

An example error code is shown in Figure 3-3.

Code: 4 2
Figure 3-3. Flashing Code Example

The flash code starts with the tens digit of the error code. After a delay, the ones
digit is flashed. A zero in the ones digit causes ten blinks. The error code in the
above example is 42.

For error code descriptions and appropriate action see the troubleshooting
chapter.

Service Port
The service port (Figure 3-1a) provides an RS-232 connection for
troubleshooting purposes. It is intended for use by Woodward certified
personnel. In case this cover is removed, torque the screws to 2.7 N‚m (24 lb-in).

NOTE
Proper torque is very important to ensure that the unit is sealed
properly.

12 Woodward
Manual 26090 RAPTOR Valve/Actuator System

Chapter 4.
Description of Operation

WARNING
Due to typical noise levels in engine environments, hearing
protection should be worn when working on or around the
RAPTOR™ valve.

Power On Procedure
The RAPTOR valve is typically continuously connected to the supply voltage.
When the key switch input is connected to a high signal (supply [+]), the
RAPTOR valve will switch its internal supply voltage on. The processor then
performs a diagnostic check. If there are no problems detected, the valve will
read the CAN ID input pins and begin sending diagnostic information on the
CAN link. The RAPTOR valve will annunciate the CAN ID code by displaying
one, two, three, or four red flashes on the diagnostic LED.

The actuator is powered and positions the valve at its minimum position. If there
is a problem detected with positioning the valve, the valve will be closed against
the minimum mechanical stop, if possible. Next, the RAPTOR valve checks for
flow parameters (Specific Gravity, K factor, and Max PWM values) in non-
volatile memory. If these values are not available, the valve will remain at
minimum position and will send diagnostic messages until these values are
received by CAN communication.

If the Specific Gravity, K and Max PWM values are available, the RAPTOR
valve will look for a Qgn (mass flow demand signal) on the CAN bus. If this
signal is not received, it will switch to the PWM secondary (backup) mass flow
demand signal. If neither signal is available the RAPTOR valve will set the flow
demand to zero internally.

Mass Flow Demand Input


The primary (CAN) and secondary (PWM) mass flow demands are continuously
monitored. If either one of the signals is received, the RAPTOR valve will wait
for 5 seconds (to ensure a stable signal) and then switch to the available signal. If
both the primary and secondary Qgn demand signals are available, the valve will
switch to the primary demand (CAN).

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RAPTOR Valve/Actuator System Manual 26090
If a valid flow demand is received, the RAPTOR valve will calculate the area
needed by the valve to provide the correct flow. This area is calculated using the
delta pressure, DP (inlet to outlet pressure differential), the absolute inlet Fuel
Gas Pressure (FGP), the Fuel Gas Temperature (FGT), the Qgn (Demand signal),
the Gas properties Sg and K, and the calibration information stored in the valve.
The actuator then positions the valve to achieve the calculated area.

NOTE
If the flow demand is zero for longer than 10 second, the RAPTOR
valve will disable the actuator coil (no power to the coil) so that the
valve will consume less power.

See Chapter 6 (Troubleshooting) for more information on non-normal operation.

Specifications

Electrical Characteristics
• Input voltage range: 18–32 Vdc
• Normal input current range (steady-state, maximum): 0.2 to 3 A
• Maximum continuous input current: 4 A
• Maximum transient input current: 6 A
• PWM Frequency: 175 to 185 Hz

Mechanical Characteristics
Valve Geometric Area
• RAPTOR 1000: 1070 mm² (1.659 in²)
• RAPTOR 2000: 2018 mm² (3.128 in²)
• See section on valve sizing for detailed information.

Weight
• RAPTOR 1000 and 2000: 43 kg (94 lbs)

Mounting
• See installation drawings

Fuel connections
• Filter requirements: less than 1.0 µm
• See installation drawings

14 Woodward
Manual 26090 RAPTOR Valve/Actuator System
Environmental
Fuel Type
The RAPTOR fuel metering valve is designed to handle pipeline, landfill, digester
and other gases consisting of gaseous hydrocarbons, carbon monoxide, carbon
dioxide, hydrogen, oxygen, nitrogen and other constituents with the following
characteristics:
1. Sulfur compounds including Hydrogen Sulfide less than 0.780e-3 ppm
2. Chlorine compounds (typically chlorofluorocarbons) less than 0.260e-3 ppm
3. Fluorine compounds (typically chlorofluorocarbons) less than 0.140e-3 ppm
4. Silicon less than 0.008e-3 ppm
5. Ammonia less than 0.039e-3 ppm
6. Water less than 80% relative
humidity
7. Oil or Liquid Hydrocarbons in mist form less than 0.016e-3 ppm
8. Particulates, including silicon less than 0.011e-3 ppm
and sized less than 1.0
µm
Pressure
• Operating inlet fuel pressure range: 3.5 to 35 kPa (0.5 to 5.1 psig) inlet
• Maximum inlet operating pressure (such as during crank): 56 kPa (8.1 psig)
• Proof pressure 82 kPa (11.9 psig)
• Burst pressure 275 kPa (39.9 psig)

Temperature
• Ambient 0–85 °C (32–185 °F)
• Fuel Temperature 0–60 °C (32–140 °F)

Vibration and Shock


Swept Sine Vibration: Per MIL-STD-810C, Method 514.2, Table 514.2-II, Curve
J (5g)
Random Vibration: Exceeds WGC RV2, 10-2000 Hz @ 0.1G2/Hz (12.8
Grms)
Shock: Per MIL-STD-810C, Method 516.2, Procedure 1, (40g)

Flow Characteristics
Accuracy
The RAPTOR control valve meters fuel accurately such that the engine starts
consistently and accelerates smoothly to idle speed. The required fuel delivery
between cranking and idle operation is within ±10% of the mass flow demand.
Throughout the load range, from idle to 100% load, the RAPTOR regulates the
fuel delivery accurately relative to the fuel flow demand in order to reduce
combustion emissions and protect the engine against detonation. The accuracy is
within ±5% of the mass flow demand from idle to 50% load and within ±2% of the
mass flow demand above 50% load.

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RAPTOR Valve/Actuator System Manual 26090
Regulatory Compliance
European Compliance for CE Mark
EMC Directive: Certified to 89/336/EEC COUNCIL DIRECTIVE of 03
May 1989 on the approximation of the laws of the
Member States relating to electromagnetic
compatibility.

Other European Compliance


Machinery Directive: Compliance as a component with 98/37/EC
COUNCIL DIRECTIVE of 23 July 1998 on the
approximation of the laws of the Member States
relating to machinery.

North American Compliance


CSA: CSA Certified for Class I, Div. 2, Groups C & D, T4
at 85°C Ambient For use in Canada and the United
States
Certificate 1093619

This product is certified as a component for use in other equipment. The final
combination is subject to acceptance by CSA International or local inspection.

Other Compliance
Meets or exceeds Woodward’s Automotive EMC Environment Test Requirements

16 Woodward
Manual 26090 RAPTOR Valve/Actuator System

Chapter 5.
Valve Sizing

The RAPTOR™ valve can be equipped with one of two trim sizes, 1000 or 2000
mm². In order to determine what trim size is needed for a particular application,
the following Valve Sizing Diagram (Figure 5-1) has been provided. In addition
to the available trim sizes, the TecJet™ gas metering valve (product
specification 36116) sizing limits have also been added to this diagram for
reference.

The RAPTOR Valve Sizing Diagram outlines the maximum flow capabilities for
a given trim size across a variety of gases and valve pressure drops. To use the
diagram, the maximum flow rate for a given application must be determined in
either a metric mass flow rate (kg/hr) or an English volume flow rate (scfm).
This value is found on the X-axis of the diagram. Choose the appropriate gas
type: natural gas, air, or specialty gas. Then choose the appropriate flow rate
units. The next step will be to find the valve pressure drop at maximum flow on
the Y-axis of the diagram. Metric (kPa) and English (psid) units are provided.
Take the flow rate value and the pressure drop value, and determine where they
cross on the diagram. This is the maximum flow rate operating point. To choose
a trim size, simply pick the closest curve to the right of the intersection point and
read what trim size the curve represents. Both the 80% and 100% flow area
curves are given in the diagram. This is to aid in determining how much flow
margin above the required maximum flow rate is available for a given trim size.
If 20% margin is required, use only the 80% flow area curve for sizing, if 0%
margin is required, use only the 100% curve, and so on. Interpolation can be
done to find intermediate margins if necessary.

As an example, let’s say the maximum flow requirement is 400 kg/hr natural gas
with a valve pressure drop of 9 kPa. Using the diagram, the closest curve to the
right of this intersection point is the RAPTOR 1000, 100% flow area.
Furthermore, a closer look shows a flow margin of approximately 15%. In this
case, the RAPTOR 1000 trim size would be appropriate.

Woodward 17
RAPTOR VALVE SIZING DIAGRAM

18
100
90
80
70
60
8
50 7
40 6
5
30
4

20 3

10
∆P (psid)

9
8
7 1

∆P (kPa)
1 TecJet50 80 % Flow Area
6
RAPTOR Valve/Actuator System

5 TecJet50 100 % Flow Area


2
4
3 Raptor 1000 80 % Flow Area 0.5
3 2 3 4 5 6
1 Raptor 1000 100 % Flow Area
4
2
5 Raptor 2000 80 % Flow Area

6 Raptor 2000 100 % Flow Area

Natural Gas (kg/hr) SG=0.6, K=1.3


1
100 200 300 400 500 600 700 800 900 1000 2000 10,000

Air or Specialty Gas (kg/hr) SG=1.0, K=1.4

Figure 5-1. RAPTOR Valve Sizing Diagram


100 200 300 400 500 600 700 800 900 1000 2000 10,000
Natural Gas (scfm) SG=0.6, K=1.3

100 200 300 400 500 600 700 800 900 1000 2000 10,000
Air or Specialty Gas (scfm) SG=1.0, K=1.4

100 200 300 400 500 600 700 800 900 1000 2000 10,000
Manual 26090

Woodward
Manual 26090 RAPTOR Valve/Actuator System

Chapter 6.
Troubleshooting

The RAPTOR™ diagnostics attempt to differentiate between RAPTOR-related


diagnostic conditions and engine-related diagnostic conditions. There are three
types of events or diagnostics:
1. Normal Run Mode
In normal run mode the RAPTOR valve has not detected any events or
diagnostics.
2. Non-normal Run Mode
In non-normal run mode the RAPTOR valve has detected an event or
diagnostic but did not shutdown.
3. Shutdown Mode
In shutdown mode the RAPTOR valve has detected an event or diagnostic
that will prohibit it from running, thus shutting itself down.

Troubleshooting a system is a complicated task. The error codes are designed to


help diagnose the problem. The error codes are not guaranteed to direct the user
to the root cause of the problem For example, there may exist problems that will
trigger more than one error code, problems that may not generate any error
codes, or problems that generate an inappropriate error code.

See Table 6-1 for detailed description of the error codes.

WARNING
The actions described may not be appropriate for all situations. The
operator should verify that any actions taken while troubleshooting
will not take equipment outside of specification, and will not damage
property or result in dangerous situations. Also check with the local
safety authority.

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RAPTOR Valve/Actuator System Manual 26090
Table 6-1. Troubleshooting Guide: Normal Run Mode
Normal Run Mode:
Flash Description Color Internal RAPTOR Possible Source Possible Action
Code Error Error Code
Log
Code
Steady The RAPTOR Green N/A All codes false None Check the engine
Flashing did not detect trouble shooting guide
any diagnostics for more information.
or events. The RAPTOR has not
detected any events
or diagnostics.

Table 6-2. Troubleshooting Guide: Non-Normal Run Mode


Non-Normal Run Mode:
Flash Description Color Internal RAPTOR Possible Source Possible Action
Code Error Error Code
Log
Code
11 The Flow Orange 11-0 Flow Not Inlet Gas pressure Check if the filters,
demand is Reached and/or the pressure valve(s) and other
greater than the across the valve restrictions upstream
maximum flow too low, excessive of the RAPTOR valve
possible for the pressure drop in are clean and
present fuel system. operating correctly.
conditions.
Inlet gas pressure Adjust the inlet gas
and/or the pressure pressure to the
across the valve is correct value.
too low, pressure
regulator problem.

Gas properties do Verify the


not match programmed gas
programmed gas parameters
parameters

The wrong size Check the valve


Raptor has been sizing for this engine.
chosen for this
application.
21 CAN controller Orange 21-0 Can Controller CAN termination Check if the CAN bus
Restarted. Restart problem has the right
termination resistor
connected at both
ends of the bus.

CAN wiring Check the CAN wiring


problem for shorts, open
connections and
intermittent contacts.

CAN noise Verify that the CAN


problem. wiring is installed
according to the
installation
instruction.
CAN bus
incompatibility with Verify ECM CAN bus
ECM, e.g., baud compatibility.
rate

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Manual 26090 RAPTOR Valve/Actuator System

Flash Description Color Internal RAPTOR Possible Source Possible Action


Code Error Error Code
Log
Code
22 No flow demand Orange 22-0 Can Qgn No Incorrect RAPTOR Check the CAN ID
(Qgn) message Signal number inputs to the
received over RAPTOR. To view the
CAN RAPTOR number,
switch the RAPTOR
off and on and count
the number of red
flashes before the
green flash. (See
CAN ID Inputs
section)

ECM is not sending Verify that the ECM is


Qgn messages, or powered up and
is not sending to sending valid Qgn
the correct messages, and that
RAPTOR number the correct RAPTOR
ID numbers are
selected.
23 The flow Orange 23-0 Can Qgn To CAN traffic Verify that there is not
demand (Qgn) Slow overload. excessive CAN traffic
update rate is that has higher
too slow priority than the
RAPTOR Qgn
message.
24 PWM signal is Orange 24-0 PWM No PWM Wiring Check the PWM input
not detected Signal problem. wiring for shorts, open
connections and
intermitted contacts.

ECM is not sending Verify that the ECM is


the PWM signal. sending a valid PWM
signal.
25 PWM frequency Orange 25-0 PWM Freq Err Wrong PWM signal Verify that the PWM
out of range from ECM signal. frequency from the
error ECM is within
specified limits.

Incompatible Contact engine


RAPTOR manufacturer.
31 Fuel temperature Orange 31-0 FGT Range Fuel temperature is Correct the fuel
below minimum Err Min below specified temperature problem
range operating range.
The RAPTOR may
not operate within
specification.
32 Fuel temperature Orange 32-0 FGT Range Fuel temperature is Correct the fuel
above maximum Err Max above specified temperature problem
range operating range.
The RAPTOR may
not operate within
specification.
33 Absolute inlet Orange 33-0 FGP Range Abnormal engine Verify that normal
gas pressure Err Min shutdown engine shutdown
below minimum sequence. sequence was
range performed

Engine used above Verify that altitude


the engine’s specification is met.
maximum specified
altitude.

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RAPTOR Valve/Actuator System Manual 26090

Flash Description Color Internal RAPTOR Possible Source Possible Action


Code Error Error Code
Log
Code
34 Absolute inlet Orange 34-0 FGP Range Pressure regulator Adjust pressure
gas pressure Err Max adjusted too high. regulator to the
above maximum correct setting.
range
Incorrectly installed Check pressure
pressure regulation regulator system
system installation.

Faulty or slow Check pressure


pressure regulator. regulator for correct
operation.
35 Delta pressure Orange 35-0 DP Range Err Incorrectly installed Check that the
below minimum Min Raptor. RAPTOR is installed
range in the right direction
according to the flow
arrow on the
nameplate.
36 Delta pressure Orange 36-0 DP Range Err Pressure regulator Adjust pressure
above maximum Max adjusted too high. regulator to the
range correct setting.
41 Integrated temp Orange 41-1 FGP Temp RAPTOR ambient Verify that the
sensor on-board Range Err Min temperature is ambient temperature
a pressure below specification. is within specification.
sensor below
minimum range
41-3 DPH Temp Fuel temperature is Verify that the fuel
Range Err Min below specification. temperature is within
specification.
42 Integrated temp Orange 42-1 FGP Temp RAPTOR ambient Verify that the
sensor on-board Range Err temperature is ambient temperature
a pressure Max above is within specification.
sensor above specification.
Maximum range
42-3 DPH Temp Fuel temperature is Verify that the fuel
Range Err above temperature is within
Max specification. specification.
44 Fuel temperature Orange 44-0 FGT Sensor The FGT sensor is Replace sensor block
sensor defect Err defective. as soon as possible.
RAPTOR is using
pressure sensor
temperature as
backup.
45 Integrated temp Orange 45-1 FGP Temp A temperature Replace sensor block
sensor on-board Sensor Err sensor in the as soon as possible.
a pressure pressure sensor is RAPTOR is using fuel
sensor defect 45-3 DPH Temp defective. temperature sensor
Sensor Err as backup.
50 Battery voltage Orange 50-0 Battery Faulty battery or Check battery and or
below minimum Voltage Low supply voltage. supply for correct
range operation.

Faulty or no battery Check battery charger


charger. for correct operation.

Faulty wiring Check wiring for the


correct size, length,
contacts, fuses.
51 Battery voltage Orange 51-0 Battery Faulty battery or Check battery or
above maximum Voltage High supply. supply for correct
range operation.

Faulty battery Check battery charger


charger or no system for correct
battery. operation.

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Manual 26090 RAPTOR Valve/Actuator System

Flash Description Color Internal RAPTOR Possible Source Possible Action


Code Error Error Code
Log
Code
63 Battery voltage Orange 63-0 Battery Faulty battery or Check battery and or
too low Voltage Too supply voltage. supply for correct
(Battery low + Low operation.
Actuator
response error) Faulty or no battery Check battery charger
charger. for correct operation.

Faulty wiring Check wiring for the


correct size, length,
contacts, fuses, and
wiring.
52 Inadequate Orange 52-0 Position Valve is Clean valve. See
valve/actuator Response Err contaminated. maintenance section
response for details.
53 The harness Orange 53-0 Raptor Nr Wiring problem. Check the CAN ID
coding was not Unstable Err inputs for intermittent
stable during contacts.
detection

Table 6-3. Troubleshooting Guide: Shut-Down Codes


Shut-Down Codes:
Flash Description Color Internal RAPTOR Possible Source Possible Action
Code Error Error Code
Log
Code
61 Gas fuel Red 61-3 Specific This is a new Every new RAPTOR
properties not Gravity Not Raptor that is connected the
programmed Prog first time will give
these errors. After the
61-1 K factor Not ECM has sent the
Prog parameters, the error
will disappear.

61-2 PWM Max Can Check if there are


Qgn Not Prog communication other CAN
problem communication error
codes.
62 Sensor module Red 62-0 Sensor Block The sensor module Verify that a sensor
not detected Not Detected is missing or the module is mounted in
sensor module the RAPTOR and that
cable is not the cable is
connected connected to the
main PCB.
WARNING—Power
down RAPTOR
before opening the
cover. The Sensor
module must not be
connected or
disconnected if the
RAPTOR is
powered.
An incompatible Contact the engine
sensor module has manufacturer
been installed

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Flash Description Color Internal RAPTOR Possible Source Possible Action


Code Error Error Code
Log
Code
64 Failure to Red 64-0 Position Err Valve is Clean valve according
position valve contaminated or to maintenance
blocked by object. procedure.

Valve is blocked by Remove RAPTOR


mechanical failure. valve and check if the
valve can be moved
by hand.

There are other Check if there is an


failures in the error code 74, Internal
RAPTOR Failure. If present,
electronics or replace RAPTOR.
wiring.
71 Sensor module Red 71-4 Two Temp Sensor module is Check if the
internal failure Sensors Err not connected. SensorBlockNotDetec
ted error code is
71-1 Sensor Block displayed. If so follow
Parameter Err SensorBlockNotDetec
ted procedure.
71-2 Sensor Block
ADC Ref Err Faulty sensor Replace sensor
module module.
71-3 SPI ADC Err
72 Absolute inlet Red 72-0 FGP Sensor Faulty fuel gas Replace sensor
gas pressure Err pressure sensor module.
sensor defect
73 Delta pressure Red 73-0 DPH Sensor Faulty delta Replace sensor
high range Err pressure sensor module.
sensor defect
74 RAPTOR Red 74-1 Software Err RAPTOR has Replace RAPTOR.
internal fault detected an
internal defect.
74-2 Valve Not
Calib Err
74-3 Calib Params
Not Prog Err
74-4 ADC Err
74-5 ADC
Reference Err
74-6 Main EEP
Write Fail
74-7 Main EEP
Read Fail
74-8 Parameter Err
74-9 Parameter
Version Err
(75) This code is only 75-1 Current
used in the Control Err
Errorlog
75-2 Current Not
Reached Err
75-3 Position
Sensor Err

24 Woodward
Manual 26090 RAPTOR Valve/Actuator System

Flash Description Color Internal RAPTOR Possible Source Possible Action


Code Error Error
Log Code
Code
75-4 Key Switch
Lock Err
75-5 Supply Neg
13 Volt Err
75-6 Supply 15 Volt
Err
75-7 Valve Calib
Range Err.
75-8 Valve Calib
Low Batt Err
Steady The power-up Red Ram Err RAPTOR has Replace RAPTOR.
flashing RAM test failed detected a defect
1Sec in the internal
RAM.
Steady The main Red Main Prog RAPTOR has not Replace RAPTOR.
flashing program is Check sum been programmed.
0.1 Sec corrupted or is Err
not programmed RAPTOR has Replace RAPTOR.
detected a change
in the program.

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26 Woodward
Manual 26090 RAPTOR Valve/Actuator System

Chapter 7.
Maintenance

Periodic cleaning may be performed. A petrochemical solvent is recommended


to clean (wash and brush) the valve. High pressure power washing is not
recommended. When cleaning of the metering element and the inside of the
valve body, do not use sharp objects that may scrape or dent the metering
element, as this could degrade the accuracy of the valve. Make sure that the
power is disconnected before removing the RAPTOR™ main connector.

RAPTOR Sensor Module Replacement Procedure


WARNING
Explosion hazard—Do not remove covers or connect/disconnect
electrical connectors unless power has been switched off or the area
is known to be non-hazardous.
Explosion hazard—Ensure that the fuel system has been de-
pressurized before removing sensor module.

CAUTION
Electronic devices contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts.
1. Discharge body static before handling the device (with power to
the device turned off, contact a grounded surface and maintain
contact while handling the device).
2. Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
3. Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.

1. Turn off power to the RAPTOR and disconnect the main cable.
2. Remove the lid by removing 18 #8 hex-headed screws around the edge and
four #8 hex-headed screws near the main connector.
3. Locate the 16-wire ribbon cable (53a) that connects the sensor module to the
main board. Remove the cable from the main board as follows: Remove the
two #6 phillips head screws (57) on the clamp at the main board end of the
sensor cable. Set aside the clamp and foam strip (55 and 56). Pull the end of
the cable directly up and off the connector pins.
4. Remove the four socket head cap screws holding the sensor module (53) to
the main housing.
5. Pull the sensor module straight up and out of the housing. Slightly twisting
the module while pulling may be required.

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RAPTOR Valve/Actuator System Manual 26090
6. Install new O-rings (50, 51, and 52) on new sensor module using petroleum
grease to hold in place. The two small O-rings (51) are placed in the two
small counterbores (pressure ports). The single medium sized O-ring (50) is
slid over the temperature sensor probe all the way to the groove (make sure
to lubricate this O-ring to ease installation of the sensor module into the
housing). The large O-ring (52) is placed in the “race-track,” held in place
with grease.
7. Lubricate the temperature sensor counterbore (24a) in the housing with
petroleum grease. Insert new sensor module into housing while ensuring that
the o-rings on the bottom remain properly seated.
8. Install the four socket head cap screws (54) holding the sensor module to the
housing, torque to 8.22 to 8.5 Nxm (73 to 75 lb-in).
9. Connect the ribbon cable (53a) to the main board by aligning the end of the
cable with the connector pins and pushing straight down. Make sure that
both rows of connector pins are engaged. Center the foam strip (55) in the
clamp (56), and install the clamp with the two #6 phillips headed screws
(57). Torque to 1.6 to 1.7 Nxm (14 to 15 lb-in).
10. Make sure that the O-rings, one around the connector and one around the
outside of the lid, are properly seated in their grooves.
11. Fasten the lid using the 18 #8 hex-headed screws around the edge and four
#8 hex-head screws around the connector. Torque both sets of screws to 3.1
to 3.2 Nxm (27 to 28 lb-in).

Figure 7-1. Installing the Sensor Module

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Manual 26090 RAPTOR Valve/Actuator System

Figure 7-2. Connecting the Sensor Module Ribbon Cable

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30 Woodward
Manual 26090 RAPTOR Valve/Actuator System

Chapter 8.
Software Upgrade

The RAPTOR™ software can be updated by loading a new program through the
service port on the RAPTOR valve.

WARNING
Explosion Hazard—Do not remove covers or connect/disconnect
electrical connectors unless power has been switched off or the area
is known to be non-hazardous.

AVERTISSEMENT
Risque d'explosion—Ne pas enlever les couvercles, ni raccorder /
débrancher les prises électriques, sans vous en assurez auparavant
que le système a bien été mis hors tension; ou que vous vous situez
bien dans une zone non explosive.

Connect a serial cable between a computer and the RAPTOR assembly. The
RAPTOR assembly has a male 9-pin Sub-D connector, and connects to the 9-pin
COM port of a PC using a null modem cable (pins 2 and 3 cross over within the
cable). Only pins 2, 3, and 5 are used (it is not a problem if the other pins are
connected).

Load the ServLink and Watch Window software on the computer. Follow the
procedure supplied with the software.

Activate the ServLink server and set the communication parameter. See server
online documentation.

RAPTOR parameters are:


• Baud rate = 19200
• Bus mode = Point to Point
• Communication = 8N1

Open a new net and wait until the net is displayed on the server screen. Start
Watch Window. Right click on the Raptor TAB. A menu will pop up. Select load
application select the file and click “ok”. Wait until Watch Window indicates
that the application has been successfully changed.

Read the documentation that is provided with the new “RAPTOR.SCP” file this
may contain additional information about changes to be made to RAPTOR valve
to work with the new software.

CAUTION
Ensure that the serial cable is removed and the port cover is replaced
after the software upgrade is complete. Electromagnetic robustness
to high strength fields is not ensured with a cable connected.
An unsafe condition could occur with improper use of these software
tools. Only trained personnel should have access to these tools.

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32 Woodward
Manual 26090 RAPTOR Valve/Actuator System

Chapter 9.
Applicable Documents

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34 Woodward
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