1. TECHNICAL SPECIFICATIONS & OPERATION MANUAL The
Contents
1. Before mounting the valve on to the engine be assured that the O Ring facing the engine is in good shape and has no infringement Also use a finger tip of grease to smoothen the O ring Mounting the valve on the engine block make sure that the mounting surface is cleaned before positioning the valve The 4 M8 nuts are tightened with 20 NM each 4014 V1 0 03 11 2006 mh dh Page 14 of 14 W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission Valve GAV 40 Specifications O6 1 1 01 dh en doc2. cl 2 f IN iN I p EU _ L A me 4 xx miewa Page 7 of 14 mh dh 4014 V1 0 03 11 2006 W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission Valve GAV 40 Specifications 06 11 01 dh en doc GAS ENGINE CONTROLS Gas Admission Valve GAV 40 HUEGLI TECH AG LTD Manual and Operation Instruction The Engine amp Genset Control Company Langenthal Switzerland www huegli tech com VALVE TEST RECORD SHEET WITH ATTACHED GRAPH ON VALVE TRAVEL MEASUREMENT RELATED TO TIME FUNCTIONAL TEST ELM 0 9mm lift W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission Valve GAV 40 Specifications O6 11 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 8 of 14 ORE Gas Admission Valve GAV 40 on HUEGLI TECH AG LTD Manual and Operation Instruction d Oe Contras Compang Langenthal Switzerland www huegli tech com Service Manual for GAV valves Tools required Allen key Nr 4 Screwdriver Nr 7 and Loctite 743 blue Clamp the GAV on the coil side in a vice Hand tighten the vice Remove the 4 allen screws holding the end flange Rotate the end flange until it can be removed After removing the end flange open the vice and turn the GAV upside down until the assembled cage falls out Note Don t drop the cage from a too high altitude since it could damage the rubber valve plat
3. M8 mounting screws to max torque 20 Nm Use a lock washer in accordance with DIN 137 A 5 he solenoid operated valve is controlled by a cable with a square section of 1 5mm The mating connector type DIN 43650 comes along with the valve 6 The gas inlet hole is recommended to be equipped with a flexible hose mounted through an adapter to avoid unnecessary stress affecting the valve body Mount and tighten the flexible hose on the adaptor prior to its installation on the valve 7 After installation all joints which can be dismantled including the inlet and outlet flange must be checked for gas leaks e g by means of a foam forming agent MAINTENANCE TROUBLESHOOTING Provided that good gas filtration in accordance with the technical parameters has been assured the valve does not need any maintenance Should any valve defect be found leakage failure to function etc the valve has to be replaced Don t repair a valve without the appropriate service instruction and the necessary knowledge Should leakage exceed allowed limits the valve is disassembled as instructed so that sealing surfaces of the valve can be checked and cleaned After assembly the valve closing tightness test is repeated and evaluated Caution The valve seat can be cleaned on the contact surface by lapping or sand paper on a flat plane The moving plate should never be cleaned by lapping or sand paper Within the warranty period repairs of the valve ma
4. Valve GAV 40 Specifications O6 11 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 6 of 14 Gas Admission Valve GAV 40 al o uy ae Wy 5 HUEGLI TECH AG LTD The Engine amp Genset Control Company Langenthal Switzerland www huegli tech com Manual and Operation Instruction SECTION DRAWING AND PARTS LIST c6vi S9 IN BuiweJq puejezilMs 1eulojsno 006 OV 54 ajeos quiessy 1YBIOM Jddy zy 9010 cS 0r AVO qd SEXSIN M S uel co N 109 do N N OSENG OLXEW M8J9S N 19205 1 N oXser c8ZNd SIN 494 507 ENE 9LXSIN M S N 80c INE SXS c Uld co 29 CXZZ v9 LO T exc9 89 N 2x99 Buiso 5 YSIP JOMO7 OcX9 N M8J9S oje d SIG Buds eJnjeuuy 8 9 Buisnou ONNANNANAY ZNV NOILVNOIS3G ALO 09 Or amt ao oO WALI 4 V
5. contamination damage and deterioration Warranty The manufacturer provides a Warranty for the purchased GAV valves which expires upon the earliest of 12 months from delivery or 2000 hours of operation Data for Delivery The order has to specify The number of units Valve type preliminary consultation with the manufacturer is advisable For accessories the replacement parts order should include a position in accordance with an outline drawing and parts list and if you need replacement parts for the valve purchased specify the valve serial number W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission Valve GAV 40 Specifications O6 1 1 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 3 of 14 Wade Hie Gas Admission Valve GAV 40 ME HUEGLI TECH AG LTD Manual and Operation Instruction Langenthal Switzerland www huegli tech com TESTING Valve closing tightness test 1 The valve is checked under conditions and with equipment corresponding with its operation 2 he test substance is filtrated b micrometer air with 2 bar pressure 3 he testing equipment consists of the test substance source air with filtration of 5 micrometers and 2 bar pressure and connecting piping DN 10 mm with a pressure gauge for measuring the valve inlet pressure 4 Criteria of allowed GAV valve closing tightness Opening of the valve plate not before O 5 bar Leakage test For a leakage test an air pressure source wi
6. frequency 12 5 Hz max Response assumes the use of an INCON control time to full open 0 003 s max time to full closed 0 003 s max Ambient temperature permanently 40 100 Ambient temperature short term 125 C max Protection class IP 64 Classification for use in atmospheres Non explosive atmosphere gas supply pressure 5 bar Max Air manifold pressure 300kPa 3 bar Max gas pressure difference 200kPa 2 bar Max Backfire pressure 5OkPa 0 5 bar Inlet gas temperature 60 C max Solenoid core resistance 38 4 5 Murgenthalstrasse 30 4900 Langenthal Solutions for combustion engines Phone 41 0 62 916 50 30 that work right from the beginning RE keh RE cee ton W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission Valve GAV 40 Specifications O6 1 1 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 1 of 14 GAS ENGINE CONTROLS Gas Admission Valve GAV 40 HUEGLI TECH AG LTD Manual and Operation Instruction Ie Engin Contra Company Langenthal Switzerland www huegli tech com 2 INSTALLATION OPERATION MAINTENANCE The GAV valve installation 1 The GAV valve Installation Operation and Maintenance Manual must be read carefully prior to installation 2 he GAV valve can be mounted on the manifold in any position 3 Make sure that the O ring at the valve inlet and outlet is clean and properly located 4 Evenly and gradually tighten the
7. acturer Full name Daniel Huegli Position President Place CH 4900 Langenthal Switzerland Date 1 November 2006 W DOKUMENTATION 2 MotorenGAV Dokumentation 4014 V 1 0 Gas Admission Valve GAV 40 Specifications 06 11 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 5 of 14 M Gas Admission Valve GAV 40 HUEGLI TECH AG LTD Manual and Operation Instruction The Eines oret Langenthal Switzerland www huegli tech com DIMENSIONAL DRAWING N o gt gt o m ae E C ES N y lt 5 _ gt oz _ lt 5 E5 S o C i Q Qu 2 JE 2 O D D lt T xi x Lo Lee oy o9 lt i 3 EX oe i N os N JaA Dco DS I lt gt 2 fal CU d DU Ds m a MES I o a z tc N E z 7 lt I E z z i d N A H 9 lt T s 9 2 I RH d Y B 2 n _ s ES SD 08 po ES y O lt as pd Jes W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission
8. cA Gas Admission Valve GAV 40 lt lt HUEGLI TECH AG LTD Manual and Operation Instruction The Sion Quies Conte Donny Langenthal Switzerland www huegli tech com 1 TECHNICAL SPECIFICATIONS amp OPERATION MANUAL The GAV solenoid operated gas admission valve is designed for use on four cycle turbo rcharged engines to govern the required amount of fuel admitted into the inlet port of the cylinder head depending on engine speed and load To govern the required amount of gas by means of the GAV the INCON electronic control system must be used for the valve control The engine load and speed are governed by the amount of gas admitted into the inlet port which is proportional to the duration of the GAV valve opening The GAV valve must assure rapid valve opening and closing a fast response to the control signal together with reliable valve opening for the whole requested period of time Consequently the GAV valve features short travel the moving valve plate is opened by the solenoid force and closed by the spring force together with gas pressure The design provides a complete seal in the closed position of the valve Caution The GAV valve must not be used as a shut off valve To serve this purpose an independent shut off gas valve must be installed Technical Specifications Operating voltage 150 VDC Cross sectional area of flow 700 sq mm Lift 0 9 mm Working medium Gaseous fuel natural gas etc Switching
9. e W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission Valve GAV 40 Specifications O6 1 1 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 9 of 14 GAS ENGINE CONTROLS Gas Admission Valve GAV 40 HUEGLI TECH AG LTD The E amp Genset Control C Manual and Operation Instruction EE n nane ompany Langenthal Switzerland www huegli tech com Clamp the cage in to the vice between the anker plate Note Don t overtorque the vice as the anker plate could suffer damage It is recommended to use soft vice clamps Unscrew the centre screw until the rubber plate can be removed Disassemble the complete cage Make sure all parts are cleaned before inspection Use non aggressive petrol for cleaning the parts 60oQ9 W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission Valve GAV 40 Specifications O6 1 1 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 10 of 14 GAS ENGINE CONTROLS Gas Admission Valve GAV 40 mm HUEGLI TECH AG LTD Manual and Operation Instruction The Engine amp Genset Control Company Langenthal Switzerland www huegli tech Inspect the rubber valve plate On top see a used plate which still can be used Below see a new valve plate Important is to watch out for cracks and tear in the rubber surface However small holes which are not larger than 0 5mm and are not located on the sealing ring marks do not affect the operation Plate which was
10. he inside of the valve is cleaned and no particulates remain on the coil surface W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission Valve GAV 40 Specifications O6 1 1 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 12 of 14 Gas Admission Valve GAV 40 HUEGLI TECH AG LTD Manual and Operation Instruction gl Cortney Company Langenthal Switzerland www huegli tech com Then insert the cage assembly There is only one direction to insert the cage since inside the valve housing a pin 15 located which has to match to the cage slit Slide the cage in to the valve If it does not go all the way down it is possible to twist the cage by hand from the gas inlet side until the cage slides in to the valve completely Insert the valve end plate Before the end flange is mounted make sure that the 2 O rings are properly installed Make sure that the O rings are in good shape otherwise replace them It is recommended to use a fingertip of grease to smoothen the O rings Tighten the end flange with an allen key Nr 4 torque 7 5NM W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission Valve GAV 40 Specifications O6 1 1 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 13 of 14 Gas Admission Valve GAV 40 HUEGLI TECH AG LTD Manual and Operation Instruction M Content Campen Langenthal Switzerland www huegli tech
11. in operation The 6 visuable New valve plate which has never been in use rings mark the sealing plate As long these No ring markings can be seen have no infringement the valve plate still meets specification W DOKUMENTATION 2 Motoren GAV Dokumentation 4014 V 1 0 Gas Admission Valve GAV 40 Specifications 06 11 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 11 of 14 ORE Gas Admission Valve GAV 40 on HUEGLI TECH AG LTD Manual and Operation Instruction d m Contras Compang Langenthal Switzerland www huegli tech com In order to make sure the lower valve plate is cleaned properly use a lapping disk or a very fine sand paper In case sand paper is used the grit number has to be between 280 320 Use a flat even surface without any bumbs Smoothly push the lower valve plate up and down with the sealing surface facing the sand paper Repeat the movement until the surface of the valve is clean It is important that only a few tenth of a millimetre of the peak radius shape are cleaned in order to seal properly IMPORTANT NOTE After lapping or using a sand paper clean the lower valve plate toroughly and assure that there are no particulates left over from the sand paper Assemble the complete cage Loctite shall be used on the rubber plate screw Loctite Nr 743 blue Tighten the rubber plate Therefore use a large screwdriver Nr 7 and tighten firmly Before inserting the cage in to the valve body ensure t
12. runner of the cylinder head depending on engine speed and load The product is intended for use in non explosive atmospheres The solenoid operated gas admission valve must not be used as a stop valve safety valve We hereby declare and confirm that A The specified product is safe under conditions of its ordinary and intended use as described in its Operation Manual and actions have been taken to assure conformity of all launched products with technical specifications basic relevant regulatory requirements and requirements of technical regulations specified in Section B B he characteristics of the product meet all applicable technical requirements set out In 1 94 9 EC Council directive of March 1994 on the approximation of the laws of the member states concerning equipment and protective systems intended for use in potentially explosive atmospheres 2 3 23 EEC council directive of February 1973 on the harmonization of the laws of the member states relating to electrical equipment designed for use within certain voltage limits 3 EN 60204 1 Safety of machinery Electrical equipment of machines EN 60204 1 4 EN 61010 1 Safety requirements for electrical equipment for measurement control and laboratory use Part 1 General requirements 5 EN50028 Electrical apparatus pro potentially explosive atmospheres Part 8 We the undersigned herby declare that the equipment specified above conforms to the above directive s Manuf
13. th the highest working pressure 2 bar will be used The test substance supply will be connected to the inlet part of the valve Leakage will be considered as satisfactory if within 3 minutes no measurable or visible foam forming agent leakage is detected which is equal to zero pressure drop once the inlet pressure ball valve is closed Supporting Documents Declaration of Conformity Dimensional drawing Section drawing and parts list Valve Test Record Sheet with attached graph on valve travel measurement related to time functional test GAV 40 valve Disassembly and Assembly Instructions for replacement of main parts Prepared by Daniel Huegli amp Bernhard Suter Date November 29 2006 W DOKUMENTATION 2 Gas Motoren GAV Dokumentation 4014 V1 0 Gas Admission Valve GAV 40 Specifications O6 1 1 0 1 dh en doc 4014 V1 0 03 11 2006 mh dh Page 4 of 14 GAS ENGINE CONTROLS Gas Admission Valve GAV 40 HUEGLI TECH AG LTD Manual and Operation Instruction amp DIRE Conte Company Langenthal Switzerland www huegli tech com DECLARATION OF CONFORMITY Manufacturers Name Huegli Tech AG Ltd Manufacturers Address Murgenthalstrasse 30 CH 4900 Langenthal Model Name Number Gas admission valves GAV 20 GAV 40 Product Description and Function The GAV solenoid operated gas admission valve is designed for use on four cycle supercharged gas engines to govern the required amount of fuel admitted into the inlet
14. y be carried out by the valve manufacturer only W DOKUMENTATION 2 Gas MotorenGAV Dokumentation 4014 V 1 0 Gas Admission Valve GAV 40 Specifications 06 11 01 dh en doc 4014 V1 0 03 11 2006 mh dh Page 2 of 14 GAS ENGINE CONTROLS Gas Admission Valve GAV 40 HUEGLI TECH AG LTD Manual and Operation Instruction Ie Engin Genes Contre Company Langenthal Switzerland www huegli tech com RECOMMENDED MAINTENANCE INTERVALS 2000 hours of operation Operational check of all valve joints which may be dismantled for leakage including inlet and outlet flange the valve is mounted on the engine and the check is made by means of a gas leakage detector or foam forming agent 3000 hours of operation Valve leakage check and valve closing tightness check in accordance with instructions 6000 hours of operation Valve O rings replacement Cage assembly replacement Lower valve plate replacement Recommended Replacement Parts O ring set positions 14 and 15 Cage assembly position 2 3 4 and 5 Lower valve plate position 6 Accessories supplied with the valve O Ring 46 X 2 Pos 14 O Ring 64 77 X 2 62 Pos 15 Mating Connector EC 1120 DIN 43650 Packaging Transport Storage The solenoid operated valve is packed in a polyethylene bag In transit and storage the packed product must be protected against mechanical damage If possible valves should be stored indoor and protected against weather and other effects to avoid their
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