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Transcript of 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.
FORM HYPERFUEL II 3-062
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
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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
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
FORM HYPERFUEL II 3-064
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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.
www.altronicinc.com 5
HYPERFUEL VALVE FUEL CONTROL SYSTEM
�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.
FORM HYPERFUEL II 3-066
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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.
www.altronicinc.com 7
HYPERFUEL VALVE FUEL CONTROL 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.
FORM HYPERFUEL II 3-068
HYPERFUEL VALVE FUEL CONTROL SYSTEM
�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.
www.altronicinc.com 9
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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 ��
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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
FORM HYPERFUEL II 3-06�2
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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
HyperFuel Valve™ SystemDistributor 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
FORM HYPERFUEL II 3-06�4
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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 +
www.altronicinc.com �5
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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
FORM HYPERFUEL II 3-06�6
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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
NORTH POLEFACING OUT
M8 THREAD
±.015
.134 ±.010
www.altronicinc.com �7
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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
'
FORM HYPERFUEL II 3-06�8
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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
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 �9
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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
FORM HYPERFUEL II 3-0620
HYPERFUEL VALVE FUEL CONTROL SYSTEM
FIG. �3 DISTRIBUTOR MODULE MOUNTING DIMENSIONS
HyperFuel Valve™ SystemDistributor 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
11.81
11.25
6.00
6.00
CONNECTORTYPE 20–29P
CONNECTORTYPE 22–14P
5/16–18THREAD
CONNECTORTYPE 20–27P
9.75
5.55
2.50 .75 .75
2.38
8.754.00
8.25
www.altronicinc.com 2�
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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).
FORM HYPERFUEL II 3-0622
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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.
www.altronicinc.com 23
HYPERFUEL VALVE FUEL CONTROL SYSTEM
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