installation instructions fuel control system · installation instructions hyperfuel valve fuel...

INSTALLATION INSTRUCTIONS HYPERFUEL VALVEFUEL CONTROL SYSTEM

www.altronicinc.com

FORM HYPERFUEL II 3-06

www.altronicinc.com �

DEVIATION FROM THESE INSTRUCTIONS MAY LEAD TO IM-PROPER ENGINE OPERATION WHICH COULD CAUSE PERSON-AL INJURY TO OPERATORS OR OTHER NEARBY PERSONNEL.WARNING:

THE HYPERFUEL VALVE SYSTEM MUST BE CONFIGURED PRIOR TO USE ON AN ENGINE. REFER TO SECTION 9.5 OF HYPERFUEL VALVE OPERATING INSTRUCTIONS (FORM HYPERFUEL OI 3-06) TO VIEW THE CURRENT CONFIGURATION. VERIFY EEPROM PROGRAMMING PRIOR TO STARTING ENGINE.

WARNING:

�.0 SYSTEM DESCRIPTION

�.� TheAltronicHyperFuelValvefuelcontrolsystemisamicroproces-sor-based electronic system applicable to slow speed, stationaryengines.Thesystemfeaturescrankshaft-triggeredtimingaccuracyand the capability to vary engine speed electronically by severalmeans,includinganexternal4-20mAcontrolsignal.Thesystemisfield-programmable and offers a variety of advanced control, emis-sionsreduction,monitoring,diagnostic,andengineprotectionfea-tures.TheHyperFuelValvesystemconsistsofthreemainparts;auserinterfaceLogicModule,anenginemountedPowerModuleandenginemountedDistributorModule.

�.2 The system is capable of outfitting applications requiring upto20individualoutputs.

�.3 TheLogicModule291200-1hasanalphanumericLCDdis-play showing the operating status, engineRPM, valve ontime,currentloopinputvalueandvalvetiming.Additionaldisplayscreensshowset-upanddiagnosticinformation.

�.4 To allow for a simple and economical installation, theHyperFuelValvecontrollerutilizesstandardAltronicmag-neticpickups,Hall-effectpickupandtriggermagnet,pickupcables,primarywiringharness(es)andjunctionbox(es).

�.5 Power requirement is 24 Vdc, 10 amperes. For all applications,

aminimumofa10amperepowersupplyshouldbeinstalled.

Fordetails,REFER TO SECTION 10.4andFIGURE 5.

http://www.altronicinc.com



HYPERFUEL VALVE FUEL CONTROL SYSTEM

2.0 SYSTEM COMPONENTS

2.� ThesystemconsistsofaLogicModule,aPowerModule,aDistribu-torModule,two(2)magneticpickupsandcables,aHall-effectpick-up and trigger magnet (4-cycle engines only), appropriate cablesandharnesses,andaHyperFuelValveforeachenginecylinder.

SEE FIGURE 3 FOR A TOTAL SYSTEM OVERVIEW

2.2 Forhazardousareaoperation,shieldedprimarycableassembliesareavailableforconnectiontotheHyperFuelvalves.

3.0 MOUNTING THE LOGIC MODULE

3.� The Logic Module is preferably panel-mounted off the engine insuchamannerastominimizeexposuretovibration.

SEE FIGURE 12 FOR DIMENSIONS

3.2 TheLogicModuleshouldbemountedwithin75feetofthePowerandDistributorModuleswhicharetobemountedontheengine.

3.3 Operatingtemperaturerangeis-40°F.to158°F.(-40°C.to70°C.).Humidity specification is 0-95%, non-condensing. Housed in a NEMA4enclosure,theLogicModuleissplashresistant;however,themountingsiteshouldprovideasmuchprotectionfrominclem-entweatheras ispractical.Avoidmounting theLCDdisplayandkeypadindirectsunlight.

4.0 MOUNTING THE POWER MODULE

4.� SEE FIGURE 11 FOR DIMENSIONS Select a mounting location meeting the following requirements:

• ON THE ENGINE • NEXT TO THE DISTRIBUTOR MODULE • WITHIN 75 FT. OF THE LOGIC MODULE • WITHIN 7 FT. OF THE PRIMARY JUNCTION BOX • THE FRONT PANEL DOOR OF THE POWER MODULE SHOULD BE EASILY ACCESSIBLE AND FREE TO SWING OPEN • THE MAXIMUM AMBIENT TEMPERATURE MUST NOT EXCEED 150°F. (65°C.)

4.2 ThePowerModuleenclosureshouldbefastenedsecurelytoarigidenginebracketusingtheshockmountsprovided.

4.3 ConnectiontotheDistributorModuleisaccomplishedvia293033-xxharness.

NOTE: If possible, keep the original shipping container(s). If future transportation or storage of the components is necessary, it/they will provide the optimum protection.

HyperFuel Valve™ SystemPower Module

PART NO. S/N

MUST BE INSTALLED PER FORM HYPERFUEL IIINSTALLÉ CONFORMÉMANT HYPERFUEL II

WARNING: KEEP COVER TIGHTWHILE CIRCUITS ARE LIVE.AVERTISSEMENT: GARDER LECOUVERCLE BIEN FERMÉLORSQUE LES.CERTIFIED

CLASS I, GROUP C & D, DIV. 2 T3INPUT POWER: 20−32 VDC, 7A MAX

ALTRONIC, INC. GIRARD, OHIO

www.altronicinc.com 3


5.0 MOUNTING THE DISTRIBUTOR MODULE

5.� SEE FIGURE 13 FOR DIMENSIONS The mounting requirements are the same as the Power Module.

5.2 TheDistributorModuleenclosureshouldbefastenedsecurelytoarigidenginebracketusingtheshockmountsprovided.

6.0 MOUNTING FLYWHEEL GEAR/DRILLING FLYWHEEL HOLES

6.� The Altronic HyperFuel Valve system requires a source of angular position pulses from the engine crankshaft. This can be a flywheel ring gear, a separately provided gear or specially drilled holes inthe flywheel. The source of position pulses must meet the following requirements:

• MUST BE FERROUS MATERIAL • DIAMETER OF 18" OR GREATER • NO. OF TEETH OR HOLES OF 180 OR GREATER • MAXIMUM RUN-OUT REFERENCED TO THE PICkUP OF .007"

SEE FIGURE 1 AND FIGURE 2

7.0 MOUNTING THE MAGNETIC PICKUPS

7.� The system requires two magnetic pickup signals: the angular posi-tionpulsesfromthegearordrilledholesandaresetpulsenearthemost advanced firing position desired for no. 1 cylinder. The pick-upsmustbemounted to rigidbrackets tomaintainanair gapof.015" ±.005" with respect to the rotating gear or flywheel. It is also important for maximum signal efficiency that the centerline of the rotatingpartpassthroughthecenterofthepickup.SEE FIGURE 1

8.0 MOUNTING THE FLYWHEEL RESET PIN

8.� Settheenginewithno.1cylindersix(6)degreesaheadofthemostadvanced fuelingpoint.Markapointon the f lywheeldirectlyoppositethepolepieceoftheresetmagneticpickup;thenrotatetheengine to a position convenient for drilling and tapping the flywheel at thepointmarkedabove.The resetpin shouldbemade fromasteel(magnetic)1/4"–20boltorstud.SEE FIGURE 1

8.2 Rotate theengine to theoriginal setpointandadjust theairgapbetweentheendoftheresetpinandthemagneticpickupat.010"usingafeelergauge.

HyperFuel Valve™ SystemDistributor Module

PART NO. S/N








NOTE: The Hall-effect signal and the reset pickup signal must occur at the same time for the system to function.

9.0 MOUNTING THE CYCLE TRIGGER (4-CYCLE ENGINE ONLY)

9.� Thetriggermagnet(260604,260605or720002)mustbemountedontheenginecamshaftorotheraccessorydriveoperatingatcam-shaftspeed.AnM8(8mm)tappedhole,0.5inches(13mm)deepisrequired — SEE FIGURE 8, FIGURE 9 or FIGURE 17 fordetails.Themag-net MUST rotate on a diameter NOT EXCEEDING:

• 6 INCHES (150 MM) FOR MAGNET 720002, OR • 15 INCHES (375 MM) FOR MAGNET 260604 OR 260605

9.2 Set the engine on the COMPRESSION stroke of no. 1 cylinder with the reset pin DIRECTLY OPPOSITE the reset pickup. The Hall-ef-fect pickup (591014-x) must be mounted DIRECTLY OPPOSITE the triggermagnet (SECTION 8.1) coincidentwith the resetpickupandpinbeinglined-up.

TheHall-effectpickupdimensionsareSHOWN ON FIGURE 15.Theairgap between the Hall-effect pickup and trigger magnet must notexceed.040"(1.0mm).

�0.0 LOGIC MODULE ELECTRICAL HOOK-UP

�0.� ThepowerconnectionstotheHyperFuelValvesystemmustbeinaccordance with the National Electrical Code or other applicablecountry code. The logic module is suitable for installation in Class I, Division 2, Group D locations.

�0.2 TheLogicModulemust have its own24Vdcpower connection.Althoughthedevicehasinternalprotectivefuses(3amp),anex-ternalfusenearthepowersourceisrecommended.SEE SECTION 12forotherdetailsregardingpoweringtheHyperFuelValvesystem.

�0.3 Powerwiringandsignal(transducers)wiringmustbeinseparateconduitsandconduitentriesintotheLogicModuletoavoidunde-siredelectricalinteraction.Allconduitentriesaresizedfora½"–14NPT male conduit fitting. Separate as follows (SEE FIGURE 6):

RIGHT CONDUIT ENTRY ......... POWER WIRING AND CABLE 293030-XX TO DISTRIBUTOR MODULE CENTER CONDUIT ENTRY ...... MAGNETIC PICkUPS AND HALL-EFFECT PICkUP LEFT CONDUIT ENTRY ........... CONTROL INPUTS, SERIAL COMMUNICATIONS, AND ALARM OUTPUTS

�0.4 RIGHT ENTRY: Input power supply wires (16 AWG minimum) should enter the right

conduit entry and connect to the24Vdc supply terminals of ter-minalblock.The interface cable293030-xx connecting theLogicModulewiththeDistributorModulealsoentersthroughtherightconduitentry.SEE FIGURE 6andFIGURE 10forconnectiondetails.



�0.5 CENTER ENTRY: Runaseparateconduitforthetwo(2)magneticpickupcableassem-

blies.TheseshouldenterthroughthecenterentryintheHyperFuelValveboxandterminateasSHOWN IN FIGURE 6.

�0.6 LEFT ENTRY: Aseparateconduitmustbeusedtotheleft-handentryforallcon-

nectionstotheuserinterfaceterminalstripsintheLogicModule.Use 24 AWG, UL style 1015 wire or shielded cable for these connec-tions; the 24 AWG wire is available from Altronic under part no. 603102(black)or603103(white).

A. SHUTDOWN INPUT (terminal 4): Usetostoptheignitionforengineshutdown.Thisinputis

openfornormaloperationofthesystemandisconnectedtoengine ground to inhibit ignition firings.

B. ALARM OUT (terminal 5), SHUTDOWN OUT (terminal 6), FUEL CONFIRM OUT (terminal 7):

Threeoutputswitchesareavailableformonitoringigni-tionsystemstatus.EachoutputconsistsofasolidstateswitchnormallyclosedtoasinglecommonrailCOMMONOUT(terminal8).Theswitchesarerated75mA@100Vdc.Theseoutputswitchesareelectricallyisolatedfromallotherterminals.Therecommendedhook-upisSHOWN IN FIGURE 6.Foroperationaldetails,refertotheHyperFuelValvesystemOperating Instructions, form HyperFuel Valve OI.

C. 4-20 MA CONTROL INPUT: The4-20mAtimingcontrolloopconnectstoterminals9(+)

and 10(−). This input is electrically isolated from all other terminals.SEE FIGURE 6

D. MISC INPUT (terminal 11):

Providesforcontrolofvarioususerselectedfeatures.Thisinputisnormallyopen;connecttoenginegroundtoactivatetheselectedfeature.SEE FIGURE 6

CAUTION: DO NOT MISTAkE THE BROWN (PIN “D”) AND LIGHT BROWN (PIN “S”) WIRES.

4-CYCLE ENGINE ONLY: The cable from the Hall-effect pickup also enters through the center entry and con-nects as SHOWN IN FIG 6.

NOTE: SHUTDOWN INPUT is a 5-volt, low-level signal.

NOTE: MISC INPUT is a5-volt, low-level signal.




NOTE: SEE SECTION 12.0 for details of the DC power connection to the Power and Distributor Modules.

��.0 POWER AND DISTRIBUTOR MODULE ELECTRICAL HOOK-UP

��.� All required connections to the HyperFuel Valve Power Module are madethroughharnessesusingmulti-pin,threadedconnectors.

��.2 17-PIN CONNECTOR: The293030-xxseriescableplugsintothe17-pinconnectoronthe

bottompanel(right)oftheDistributorModule.Thebottompanel(left) 14-pin connector requires cable 293033-xx which connects to the 14-pin connector on the Power Module. Insert the connector intothemodulereceptaclesandtightenhand-tight;thencarefullytightenanadditionalone-sixthturnwithawrench.

��.3 19-PIN CONNECTOR(S): REFER TO SECTION 13.1forhookupdetailsfortheoutputconnector(s)

oftheDistributorModule.

�2.0 DC POWER HOOKUP - 293030-XX CABLE

�2.� ThepowerconnectionstotheHyperFuelValvesystemmustbeinaccordance with the National Electrical Code or other applicablecountry code. The HyperFuel is suitable for installation in Class I, Division 2, Group D locations.

�2.2 It is necessary to split the control cable and power leads of the 293030-xxcableinanengine-mountedjunctionboxorconduittee.This box should be separate from the main junction box used toterminatetheoutputharness(es)tothefuelvalves.

Thejunctionbox(REFER TO FIGURE 3) shouldhavethree(3)½"con-duit entries:

1ST ENTRY: CONDUIT FITTING OF 293030-XX SERIES CONNECTING CABLE FROM THE DISTRIBUTOR MODULE.

2ND ENTRY: TWO LEADS FROM A SOURCE OF NOMINAL 24 VDC (24-28 VDC). THE NEGATIVE OF THE 24 VDC SUPPLY MUST BE COMMON WITH ENGINE GROUND. REFER TO FIGURE 5 FOR DETAILS OF THE POWER HOOkUP.

3RD ENTRY: THE GRAY JACkETED CONTROL CABLE FROM THE 293030-XX SERIES CABLE CONNECTING TO LOGIC MODULE.

�2.3 The HyperFuel Valve system can be powered in one of two ways:

• 24 VOLT BATTERY WITH CHARGER

• DC POWER SUPPLY CAPABLE OF FURNISHING 24-28 VDC. A MINIMUM CURRENT CAPABILITY OF 10 AMPS IS REqUIRED. SEE FIGURE 5

NOTE: The negative (−) of the 24 Vdc supply MUST BE COMMON WITH ENGINE GROUND. Engines using pos-itive ground DC accessories or starter motors will require a separate, dedicated power supply for the HyperFuel Valve system.



IMPORTANT!

ALTHOUGH THE DEVICE HAS INTERNAL PROTECTIVE FUSES (30 AMP), TWO EXTERNAL 50 AMP FUSES NEAR THE POWER SOURCE ARE RECOMMENDED FOR THE PROTECTION OF ENGINE AND BUILDING WIRING. THIS WILL REDUCE THE POS-SIBILITY OF A FIRE OCCURRING IN THE EVENT OF A SHORT CIRCUIT IN THE WIRING.

WARNING:

ForproperoperationoftheHyperFuelValvesystem,voltageandcur-rent supplied must be sufficient during all selected modes of opera-tion.FIGURE 5 PROVIDES DETAILS regarding the DC power hook-up:

1. CURRENT DRAW PER SYSTEM — formula varies depending on number of outputs used, engine cycle and RPM.

2. MINIMUM WIRE GAUGE REqUIREMENTS — CHART 1 OF FIGURE 5 gives the requirement vs. the length of run between the power source and the HyperFuel Valve Power Module.

3. MULTIPLE ENGINE INSTALLATIONS — Multiply current required per system by the number of engines. Where more than one engine is powered from a common power source, SEE CHART 2 OF FIGURE 5 for the minimum wire size required.

�3.0 PRIMARY WIRING

�3.� Themainwiringharness(293023-x,293026-x,or293027-x)con-nects the Distributor Module to the engine junction box. If it is de-sired to shorten the conduit lengthof theharness, SEE FIGURE 14.Insert the connector into the Altronic HyperFuel Valve Distributor Modulereceptacleandtightenhand-tight;thencarefullytightenanadditionalone-sixthturnwithawrench.

FOR DISTRIBUTOR MODULE 291220-1 SEE FIGURE 4 (x1 = connector 1; x2 = connector 2)

Connector: A1 A2 B1 B2 C1 C2 D1 D2 E1 E2

Engine:

Connector: F1 F2 k1 k2 L1 L2 M1 M2 N1 N2

Engine:

�3.2 Connecttheharnessleadsinthejunctionboxinaccordancewiththe engine’s firing order. Screw-type terminals are recommended. Theleadsfromthejunctionboxcorrespondingtotheabovesystemoutputsconnecttothefuelvalvecoilpositive(+)terminals.The“J”leadandthecommonvalvegroundlead(s)connectingthenegative(-)terminalsofthevalvecoilsmustbegroundedtotheengineinthejunctionbox.OnV-engines, runa separate commonground leadforeachbank.Separategroundconnectionsinthejunctionboxarerecommended.

NOTE: Terminal strips should be capable of handling no. 12 gauge or larger stranded wire and 50 Amp peak cur-rent pulses with minimal losses.




�3.3 Primarywireshouldbeno.12gaugestranded,tinnedcopperwireor heavier. The insulation should have a minimum thickness of.016" and be rated 105° C. or higher. PVC or polyolefin insulations are recommended. Belden 9912 or equivalent meets these specifica-tions.Allprimarywiringshouldbeprotectedfromphysicaldamageandvibration.

�3.4 Allunusedprimarywiresshouldbeindividuallytapedsothattheyare insulated from ground and each other. The unused primarywirescanthenbetie-wrappedtogetherforacleaninstallation.

�4.0 SHUTDOWN WIRING

�4.� Toshut-offtheDC-poweredHyperFuelValvesystem,aspecialin-put (SHUTDOWN INPUT – terminal 4) in the Logic Module is pro-vided.Thisinputisopenfornormaloperationandisconnectedtoenginegroundtoinitiateafuelsystemshutdown.Useaswitchrated24Vdc,0.5amps.REFER TO SECTION 10.6AandFIGURE 6fordetails.



FIG. � PICKUP MOUNTING DETAIL

TOOTH/HOLEPICKUP

ROTA

TIO

N

1.0" MIN.

BAR HOLES

90º

.10

.31

.75

RESET PROJECTIONWITH NUT

RESET PROJECTIONWITH 1/4 – 20 JAMNUT

AIR GAP.015" OPTIMUM

NOTE:VISUAL PROPORTION OF THIS ILLUSTRATION WILL CHANGE WITH VARIATIONS IN GEAR AND FLYWHEEL SIZE AND RELATIONSHIP

NOTE:FLYWHEEL GUARD NOT SHOWN FOR CLARITY

FLYWHEEL

DRILLED HOLESIN FLYWHEEL

ORRING GEAR

PATH OF ROTATION ISPERPENDICULAR TO FLAT OF STUD

GRIND AWAY BOLT HEADMATERIAL SHOWN DASHED

(USING 1/4 – 20 BOLT)

TAP 5/8" – 18FOR PICKUPS

MOUNTING BRACKET.250" STEEL OR EQUIV.

ENGINE BLOCK

RESETPICKUP

EDGE VIEW RESET PROJECTION


FORM HYPERFUEL II 3-06�0


FIG. 2 FLYWHEEL HOLE DRILLINGFL

YWHE

EL L

AYO

UT

MAR

K “A

” AND

MEA

SURE

CIRC

UMFE

RENC

E A→

A

MEA

SURE

1/2

A→A

AND

MAR

K “B

”NO

TE: A

→B

= B→

A

MEA

SURE

1/2

A→B

AND

MAR

K “C

”M

EASU

RE A

ND M

ARK

“D” I

N TH

E SA

ME

MAN

NER

MEA

SURE

1/2

A→C

AND

MAR

K “E

”M

EASU

RE A

ND M

ARK

“F”,

“G” A

ND “H

” IN

THE

SAM

E M

ANNE

R

NOTE

: CO

NFIR

M IN

TERV

ALS

BETW

EEN

M

ARKS

ARE

NO

W E

QUA

L

MEA

SURE

THE

LEN

GTH

A→

E, D

IVID

EBY

45,

AND

BEG

INNI

NG W

ITH

“A”

MAR

K O

FF IN

TERV

ALS

OF

THIS

LENG

TH T

O “E

”. CO

UNTI

NG “A

”AN

D “E

” THE

RE S

HOUL

D BE

46

MAR

KS.

DO T

HE R

EMAI

NING

7 S

ECTI

ONS

IN T

HESA

ME

MAN

NER.

“A”

“B”

“C”“D

”

“E”

“F”

“G”

“H”“A

”“B

”

“C”

“D”

“E”

PRO

CEDU

RE F

OR

DRIL

LING

360

HOLE

S IN

ENG

INE

FLYW

HEEL

DRIL

LING

DET

AIL

“A”

“B”

“A”

BAR

HOLE

S

“A”

DIST

ANCE

TIM

ING

HO

LES

1" MIN

.1" MIN

.

NOTE

: IF

2/3

“N’ W

ORK

S O

UT T

O B

E BE

TWEE

N ST

ANDA

RD

DR

ILL

SIZE

S –

USE

NEXT

SIZ

E LA

RGER

.

FLYW

HEEL

RESE

T PR

OJE

CTIO

N

1/3

“N”

2/3

“N”

“N”

.50

MIN

.TI

MIN

GHO

LES

“N” =

A T

O E

4

5

www.altronicinc.com ��


FIG. 3 HYPERFUEL VALVE SYSTEM BASIC LAYOUT

+-

* NO

TE: I

TEM

S RE

QUI

RED

O

NLY

FOR

4-CY

CLE

EN

GIN

ES

* CAM

SHAF

T

MO

UNTE

D

MAG

NET

* HAL

L-EF

FECT

CY

CLE

SENS

OR

59

1014

CABL

E

DRIL

LED

HOLE

OR

GEA

R TO

OTH

MAG

NETI

CPI

CKUP

6911

18

RESE

TM

AGNE

TIC

PICK

UP69

1118

TIM

ING

SIG

NAL

CONT

ROL

I/ORS

-485

LOG

IC M

ODU

LE29

1200

–1

24 V

DC

CABL

E 29

3030

CABL

E 29

3033

POW

ERM

ODU

LE29

1201

–1

DIST

RIBU

TOR

MO

DULE

2912

20–1

24 V

DCPO

WER

SUPP

LY

TO H

yper

Fuel

VAL

VES

JUNC

TIO

NBO

XJU

NCTI

ON

BOX




FIG. 4 VALVE HOOK-UP DIAGRAM

291220–1DISTRIBUTOR MODULE

CONNECTOR 1 CONNECTOR 2

NO. MEMORY VALVE DRIVE ORDER OUTPUTS CODE 4 D2x, D4x A1–A2–B1–B2 5 E2A, E4A A1–A2–B1–B2–C1 6 F2x, F4x A1–A2–B1–B2–C1–C2 7 G2A, G4A A1–A2–B1–B2–C1–C2–D1 8 H2x, H4x A1–A2–B1–B2–C1–C2–D1–D2 9 12A, 14A A1–A2–B1–B2–C1–C2–D1–D2–E1 10 J2x, J4x A1–A2–B1–B2–C1–C2–D1–D2–E1–E2 12 L2x, L4x A1–A2–B1–B2–C1–C2–D1–D2–E1–E2–F1–F2 14 N2x, N4x A1–A2–B1–B2–C1–C2–D1–D2–E1–E2–F1–F2–K1–K2 16 P2x, P4x A1–A2–B1–B2–C1–C2–D1–D2–E1–E2–F1–F2–K1–K2–L1–L2 18 R2x, R4x A1–A2–B1–B2–C1–C2–D1–D2–E1–E2–F1–F2–K1–K2–L1–L2–M1–M2 20 T2x, T4x A1–A2–B1–B2–C1–C2–D1–D2–E1–E2–F1–F2–K1–K2–L1–L2–M1–M2–N1–N2

www.altronicinc.com �3


FIG. 5 DC POWER HOOK-UP

D.C.

PO

WER

SO

URCE

4-CY

CLE

N 3 X

RPM

6

00

N 3 X

RPM

3

00

2-CY

CLE

DIST

ANCE

IN F

EET

CHAR

T 1

CHAR

T 2

MIN

IMUM

WIR

E G

AUG

EM

INIM

UMW

IRE

GAU

GE

NO. O

F SY

STEM

SX

DIST

ANCE

IN F

EET

AVER

AGE

CURR

ENT

DRAW

OPE

RATI

NG V

OLT

AGE

REQ

UIRE

MEN

T:24

–28

VDC

Hype

rFue

lDI

STRI

BUTO

R M

ODU

LE

ALTE

RNAT

OR

BATT

ERY

REG

ULAT

OR

BATT

ERY

FUSE

RAT

ING

:50

AM

P

NOTE

: AB

OVE

400

, USE

MUL

TIPL

E PA

IRS

OF

WIR

ES F

ROM

TH

E PO

WER

SO

URCE

TO

THE

ENG

INE

ROO

M.

1. I

T IS

REC

OM

MEN

DED

THAT

EAC

H SY

STEM

BE

CONN

ECTE

D

SEPA

RATE

LY B

ACK

TO T

HE P

OW

ER S

OUR

CE. U

SE C

HART

1

TO D

ETER

MIN

E TH

E W

IRE

SIZE

(GAU

GE)

REQ

UIRE

D.

2. I

F M

ULTI

PLE

UNIT

S AR

E PO

WER

ED F

ROM

A S

OUR

CE L

OCA

TED

IN A

SEP

ARAT

E

BUIL

DING

, USE

CHA

RT 2

TO

DET

ERM

INE

THE

WIR

E SI

ZE (G

AUG

E) R

EQUI

RED

BE

TWEE

N TH

E PO

WER

SO

URCE

AND

THE

ENG

INE

ROO

M. C

REAT

E A

COM

MO

N

POW

ER H

OO

KUP

POIN

T IN

THE

ENG

INE

ROO

M; T

HEN

USE

CHAR

T 1

TO D

ETER

MIN

E

THE

WIR

E SI

ZE R

EQUI

RED

FRO

M T

HIS

COM

MO

N PO

INT

TO E

ACH

MO

DULE

.

BATT

ERY

CHAR

GER

POW

ER S

UPPL

Y

N =

NUM

BER

OF

OUT

PUTS

USE

D.M

ULTI

PLY

BY N

UMBE

R O

F EN

GIN

ES F

OR

TOTA

L RE

QUI

REM

ENT.

POW

ER S

UPPL

Y SP

EC: S

EE C

HART

BEL

OW

.

UP T

O 2

5 12

AW

G26

–40

10 A

WG

41–6

5 8

AWG

66–1

00

6 AW

G10

1–16

0 4

AWG

26–4

0 8

AWG

41–6

5 6

AWG

66–1

00

4 AW

G


PART NO. S/N








FIG. 6 LOGIC MODULE WIRING DIAGRAM

USER

INPU

T,CL

OSE

TO

STO

P Hy

perF

uel

VALV

E SY

STEM

CABL

E 29

3030

USER

INPU

T, C

LOSE

TO

ACTI

VE S

ELEC

TED

FEAT

URE(

S)

NO

TE:

IS

OLA

TED

TERM

INAL

S W

HICH

ARE

NO

T CO

NNEC

TED

TO G

ROUN

D

OR

±24

VOLT

SUP

PLY.

THE

SE T

ERM

INAL

S CA

N BE

REF

EREN

CED

TO

AN

EXTE

RNAL

ISO

LATE

D SU

PPLY

IF R

EQUI

RED.

LIG

HTBR

OW

N“S

”

PINK “T”

4–20

mA

RS–4

85TO

PC

24 V

24 V

OLT

SUPP

LY

4–CY

CLE

PICK

UPM

AGNE

TIC

PICK

UPS

ENG

INE

GRO

UND

CABL

E 29

3030

OUT

PUT

MO

DULE

CO

NNEC

TIO

NS

R

P N

M

L K

J

H

G

F E

D

C S

h

PICK

UPS

1 2

3

4

5

6

7 8

S

T

SERIA

L POR

TSE

TUP O

NLY

PANE

L I/O

EXTE

RNAL

CONT

ROL

– +

INPU

TS

9 10

11

POWE

R

CR

CRCR

A B

C

Sh

A B

Sh

A

B

**

+ 24VDC– 24VDC (GND)SHIELDVSS (BLACK)DSA (BROWN)DSB (RED)REA (ORANGE)REB (YELLOW)E1 (GREEN)E2 (BLUE)E3 (VIOLET)SKIP (GREY)FIRE A (WHITE)FIRE B (RED/BLACK)RESET (RED/GREEN)GTO (RED/YELLOW)

SHIELDHALL-EFFECT – RETURNHALL-EFFECT + SUPPLYHALL-EFFECT OUTPUTRESET INPUT (BLACK)RESET INPUT (RED)SHIELDG. T. INPUT (BLACK)G. T. INPUT (RED)MISC INPUTCURRENT LOOP INPUT –CURRENT LOOP INPUT +

RS485 – (PINK)RS485 – (LT. BRN)

COMMON OUTFUEL CONFIRM OUTSHUTDOWN OUTALARM OUTSHUTDOWN INPUT

SHIELDSERIAL RS485 –SERIAL RS485 +



FIG. 7 WIRING DIAGRAM — SHIELDEDRI

GID

CO

NDUI

TCO

NDUI

T “T

”

A

A

A

A

A

JJ

A

A

A

A

A

B

B

B

B

B

B

B

B

B

B

FLEX

IBLE

O

R RI

GID

CO

NDUI

T

SHIE

LDED

PRI

MAR

Y LE

AD59

3022

, 593

027

JUNC

TIO

N BO

XG

ROUN

D TO

ENG

INE

AT E

ND C

YLIN

DERS

Hype

rFue

lVA

LVE

HARN

ESS

CONN

ECTO

R

HARN

ESS

CONN

ECTO

R

SEPA

RATE

GRO

UNDS

IN J

UNCT

ION

BOXE

SAS

SHO

WN

J-BO

X

J-BO

X

Hype

rFue

lDI

STRI

BUTO

RM

ODU

LE

NOTE

:

POW

ER M

ODU

LE

MUS

T BE

GRO

UNDE

D




FIG. 8 MAGNET ASSEMBLY

FIG. 9 MAGNET ASSEMBLY, HEX

.39

.75DIA.

1.334

NORTH POLEFACING OUT

M8 THREAD

±.015

.134 ±.010

.39

.75 HEX.

1.334


M8 THREAD

±.015

.134 ±.010



FIG. �0 CABLE ASSEMBLY, SHIELDED P/N 293030-XX

HARN

ESS

CONN

ECTO

R PI

NAR

RANG

EMEN

T

20–2

9S

L1

L2

3.0"

1/2–

14 N

PT

SHIE

LD D

RAIN

WIR

E

* CA

UTIO

N:

DO N

OT

CONF

USE

THE

BRO

WN

(PIN

D)

AN

D LI

GHT

BRO

WN

(PIN

S) W

IRES

WIR

E CO

LOR

PIN

RED

+ +

+ +

AW

HITE

– –

– –

B

BLAC

K C

BRO

WN

DRE

D E

ORA

NGE

FYE

LLO

W

GG

REEN

H

BLUE

J

VIO

LET

KG

RAY

LW

HITE

M

RED/

BLK

NRE

D/G

RN

PRE

D/YE

L R

LT B

RN

SPI

NK

T

* *

PA

RT N

O.

L1 L

ENG

TH

L2 L

ENG

TH 2

9303

0–25

72

" 25

' 2

9303

0–50

72

" 50

' 2

9303

0–75

72

" 75

'




FIG. �� POWER MODULE MOUNTING DIMENSIONS

11.81

11.25

6.00

6.00

9.75

8.25

8.75

5/16–18THREAD

2.50

5.55

CONNECTORTYPE 20–27P

.75 .75

HyperFuel Valve™ SystemPower Module

PART NO. S/N







FIG. �2 LOGIC MODULE MOUNTING DIMENSIONS

HyperFuel Valve™ SystemControl Module

AUTO

F2 NEXT

ESC

CAL CYLBIAS

ALARMACK

F1 FUELTIMING

DIAG

SETUP

RESET

ENTER

MANSEL

.257 DIA. THRUFOR 1/4–20 MOUNTING SCREW(TYP 4)

.875 DIA. THRU1/2" NPT(TYP 3)

1.88

3.00

12.00

8.00

10.31

11.56

10.00

2.00 2.00

6.19

4.78

.38

1.41

12.31 12.78 13.53

SPECIFICATIONSOUTPUTS: 3 SOLID-STATE RELAY OUTPUTS (FUEL, ALARM, SHUTDOWN) ARTED AT 100 VDC/AC @ 75 mA (SINKING) 1 14 LINE DIGITAL BUS (TO OUTPUT MODULE) 1 5 LINE DIGITAL BUS (FUTURE EXPANSION MODULE)

INPUTS: 1 HALL-EFFECT PICK-UP INPUT 2 MAGNETIC PICK-UP INPUTS (GEAR, TOOTH, RESET) 1 4–20 mA LOOP INPUT (ISOLATED) 2 DIGITAL INPUTS (GROUND TO ACTIVATE) (SHUTDOWN, MULTI-FUNCTION CONFIGURABLE) 2 RS485 SERIAL COMMUNICATIONS PORTS (CONTROL MODULE, FUTURE EXPANSION MODULE)

DISPLAY: 2 X 16 BACKLIT LCD MODULE

POWER: 20–32 VDC, 10 WATTS

PACKAGE: NEMA 4, WEATHERPROOF ENCLOSURE

FIELD CONNECTIONS: PLUG-IN TERMINAL STRIPS IN BOX ACCESSED VIA PLATE IN BOTTOM

POWER ALARM




FIG. �3 DISTRIBUTOR MODULE MOUNTING DIMENSIONS


PART NO. S/N





11.81

11.25

6.00

6.00



5/16–18THREAD


9.75

5.55

2.50 .75 .75

2.38

8.754.00

8.25

www.altronicinc.com 2�


FIG. �4 SHIELDED HARNESS CONDUIT LENGTH ADJUSTMENT

1

1

2

2

3

45

TO S

HORT

EN H

ARNE

SS

1.

LOO

SEN

AND

DISE

NGAG

E NU

T (2

) AND

REM

OVE

CO

NDUI

T (1

)

COM

PLET

ELY

FRO

M C

ONN

ECTO

R AN

D HA

RNES

S AS

SEM

BLY

2.

REM

OVE

ITEM

S (5

), (4

), AN

D (2

) IN

THAT

ORD

ER F

ROM

CO

NDUI

T (1

).

NOTE

THR

EADS

ON

(5).

3.

CUT

COND

UIT

TO L

ENG

TH W

ITH

HACK

SAW

AND

DRE

SS W

ITH

FILE

TO

IN

SURE

A C

LEAN

, SQ

UARE

END

. REM

OVE

FIL

ING

S FR

OM

INSI

DE C

OND

UIT.

4.

REIN

STAL

L IT

EMS

(2),

(4),

AND

(5) I

N TH

AT O

RDER

.

5.

INST

ALL

REAS

SEM

BLED

CO

NDUI

T IN

TO (3

) AND

TIG

HTEN

(2).




FIG. �5 HALL-EFFECT PICKUP

5/8–18 UNF–2A303 STAINLESS STEEL BODY

304 STAINLESSSTEEL COLLAR15/16 S.S. HEX. NUT

+.016–.031

1.5539.4mm

±.05 1.7544.5mm

.800 DIA +.02520.3mm –.000

(APPROXIMATECONNECTOR CLEARANCE)

10SL–3P CONNECTORNICKEL-PLATED STEEL

TYPICAL MATINGCONNECTOR:MS3106A–10SL–3S

A

BC

T

L

ALTRONIC P/N T L 591014–2 2.50"/63.5mm 4.05"/102.8mm 59101–4 4.50"/114.3mm 6.05"/153.7mm

SPECIFICATIONS:

SUPPLY VOLTAGE....... 5 TO 8 VOLTS D.C.

SUPPLY CURRENT...... 50 mA. MAX.

OUTPUT VOLTAGE @ 5 mA. ........................ SUPPLY VOLTAGE MINUS 1.0 VOLT MAX.

OUTPUT CURRENTSOURCING ................... 10 mA. MAX.

STORAGE AND OPERATING TEMP....... –40º C TO +125º C –40º F TO +257º F

ENCAPSULATED IN GLASS-FILLED EPOXYSUITABLE FOR ENGINE OIL OR OTHERNON-CONDUCTIVE MEDIA ONLY.MAXIMUM OPERATINGPRESSURE................... 50 psi DIFFERENTIAL

NOTE: 1. NORTH POLE OF MAGNET MUST FACE SENSING END WITH AIR GAP OF .030/.040 (.76/1.0mm).

2. CENTERLINE OF MAGNET’S ROTATION MUST RUN THROUGH CENTERLINE OF PICKUP.

TYPICAL OUTPUT WAVEFORM

TRIGGERED BY THE NORTH POLE OFMAGNET 5 VOLT SUPPLY 1K? LOAD

SCHEMATIC

OUTPUT

+ SUPPLY

– SUPPLY

90%

10%TF = 2.0?STR = 0.5?S

A

B

C

47?

10?

8.2V

H.E.



FIG. �6 MAGNETIC PICKUP

5/8–18 UNF–2A.106 DIA.

+.016–.031

1.5539.4mm

±.05 1.7544.5mm

.800 DIA +.02520.3mm –.000

(APPROXIMATECONNECTOR CLEARANCE)

1N52378.2V ±5%(TYP 4)

GS02 HERMETICALLYSEALED CONNECTOR

A B

T

L

ALTRONIC P/N T L 691118–1 1.75"/44.5mm 3.30"/83.3mm 691118–2 2.50"/63.5mm 4.05"/102.8mm 691118–3 3.0"/76.2mm 4.55"/115.6mm 691118–4 4.5"/114.3mm 6.05"/153.7mm 691118–6 6.0"/152.4mm 7.55"/191.8mm

ELECTRICAL DATA *MAX. COIL INDUCTANCE 420 mH

MIN. COIL RESISTANCE 900?

*NOTE: ELECTRICAL VALUES GIVEN ARE ABSOLUTE RATINGS ASSURED 100% BY TEST.

A

B




FIG. �7 MAGNET ASSEMBLY

M8–1.25 THREAD

3/8 HEX

.709 REF(18)

(8)(10).315.394


installation instructions fuel control system · installation instructions hyperfuel valve fuel...

Documents