T.M.

C173255

TECHNICAL MANUAL

OPERATION AND
MAINTENANCE INSTRUCTIONS

ABSOLUTE PRESSURE
TRANSDUCER ASSEMBLY
MODEL NUMBER C173255

PROPRIETARY INFORMATION NOTICE: – THE INFORMATION CONTAINED HEREIN

IS THE PROPERTY OF WHITTAKER CONTROLS, A UNIT OF WHITTAKER CORPORATION,
AND DISCLOSURE OF THE CONTENTS TO OTHERS IS GIVEN IN CONFIDENCE. THIS
MATERIAL MUST NOT BE REPRODUCED OR COPIED, OR OTHERWISE DISCLOSED IN
WHOLE OR IN PART WITHOUT THE APPROVAL OF WHITTAKER CONTROLS, NORTH
HOLLYWOOD, CALIFORNIA, U.S.A.

1 MAY 1998
 T.M. C173255
1 MAY 1998

Reproduction of the information or illustrations contained in this publication is not permitted, without written
permission from the publisher: Whittaker Controls, 12838 Saticoy Street, North Hollywood, California
90605, U.S.A.

LIST OF EFFECTIVE PAGES

Insert latest changed pages; dispose of superseded pages.

NOTE: On a changed page, the portion of text affected by the change is indicated by a vertical line or
other change symbol in the outer margin of the page. Changes to illustrations are indicated by miniature
pointing hands. Changes to wiring diagrams are indicated by shaded areas.

Dates of issue for original and changed pages are as follows:

Original 1 . . . . . . . . . . . . 1 MAY 1998

Total number of pages in this manual is 17 consisting of the following:

Page #Change Page #Change Page #Change Page #Change

No. No. No. No. No. No. No. No.

Title . . . . . . . . . . . . . 0 1-1 – 1-2 . . . . . . . . . 0 4-1 . . . . . . . . . . . . 0 6-1 . . . . . . . . . . . . . 0

A ...............0 2-1 – 2-3 . . . . . . . . . 0 5-1 – 5-2 . . . . . . . . . 0 7-1 – 7-2 . . . . . . . . . 0
i – iii . . . . . . . . . . . . 0 3-1 . . . . . . . . . . . . . 0

#Zero in this column indicates an original page.

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TABLE OF CONTENTS

Section Paragraph/Title Page

SAFETY SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . iii

I INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-1. Purpose of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-4. Scope of Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
1-7. Symbols and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

II SYSTEM DESCRIPTION AND OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

2-1. System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
2-6. Absolute Pressure Transducer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

III INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

3-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-3. Pressure Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-5. Electrical Interfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-7. Shielding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
3-9. Cable Entries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
3-11. Cable Wire Sizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

IV FAULT ISOLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

4-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
4-3. Pressure Transducers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

V MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-4. Repair Tasks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-5. Absolute Pressure Transducer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-6. Pressure Transducer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
5-9. Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

VI MAINTENANCE PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

6-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
6-3. Maintenance parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

VII ELECTRICAL WIRING INFORMATION AND INTERCONNECTION DIAGRAMS . . . . . . . . . 7-1

7-1. General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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LIST OF ILLUSTRATIONS
Figure Title Page

2-1. Absolute Pressure Transducer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

7-1. Absolute Pressure Transducer Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2

LIST OF TABLES
Table Title Page

1-1. Characteristics/Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

2-1. Pressure Transducer Specifications/Characteristics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
6-1. Recommended Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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SAFETY SUMMARY

GENERAL

The following are general safety precautions that are not related to specific procedures and therefore
do not appear elsewhere in this publication. These are recommended precautions that personnel must
understand and apply during many phases of maintenance.

WEAR PROTECTIVE CLOTHING

Wear protective clothing (gloves, apron, etc.) approved for the materials and tools being used.

USE APPROVED SAFETY EQUIPMENT

When cleaners and primers are being applied, approved explosion-proof lights, blowers, and other
equipment shall be used. Make sure that fire fighting equipment is readily available and in working order.

GIVE CLEANERS SPECIAL CARE

Keep cleaners in special polyethylene bottles or in safety cans and in minimum quantities. Discard soil-
ed cleaning rags into safety cans.

ELECTRICAL SYSTEM PRECAUTIONS

The equipment contains a 12 VDC electrical system. Prior to performing electrical repairs after testing,
make sure that the 12 VDC power source is disconnected prior to attempting removal or disassembly of
any electrical components. This will protect personnel from possible electric shock as well as protecting
the equipment from possible damage.

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1 MAY 1998

SECTION I

INTRODUCTION

1-1. PURPOSE OF MANUAL.

1-2. This technical manual contains instructions for operation and maintenance of the Absolute Pressure
Transducer Assembly (transducer assembly).

1-3. The transducer assembly is a component of a fuel metering system used in conjunction with the
General Electric Mark V LM Engine Control System to control delivery of natural gas to individual combus-
tor manifolds of a Gas Turbine Engine. Refer to Table 1-1 for specifications/characteristics.

1-4. SCOPE OF MANUAL.

1-5. This manual is intended to provide information in sufficient detail to permit proper operation and
maintenance of the transducer assembly.

1-6. The technical manual is divided into seven sections:

Section I – Introduction – Describes the purpose and scope of this manual.

Section II – System Description and Principles of Operation – Contains a physical description

of the equipment together with explanations of its operation and component functions and character-
istics.

Section III – Installation – Provides information for installing, connecting, and preparing the equip-
ment for use.

Section IV – Fault Isolation – Contains procedures for finding the cause of a malfunction.

Section V – Maintenance – Provides instructions for adjustment, and replacement of defective

components.

Section VI – Maintenance Parts List – Contains a list of spare parts recommended for on-site
support of the equipment.

Section VII – Diagrams – Contains the necessary wiring schematic diagrams.

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1-7. SYMBOLS AND ABBREVIATIONS.

1-8. Symbols and abbreviations used in this technical manual are as follows:

AWG American Wire Gage mm Millimeter

C Centigrade (Celsius) NPT National Pipe Thread
DC Direct current P/N Part Number
F Fahrenheit psi Pounds per square inch
Hz Hertz psia Pounds per square inch, absolute
kg Kilogram psid Pounds per square inch, differential
kg/s Kilograms/second psig Pounds per square inch, gage
kPa KiloPascal SPDT Single-pole, double-throw
LVDT Linear variable differential transformer VDC Volts direct current

Table 1-1. Characteristics/Specifications

Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General Electric LM1600, LM2500, LM2500+

and LM6000 Gas Turbine Engines

Service Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural Gas (per MID-TD-0000-1)

Electrical Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC (9 to 16 VDC)

Temperatures
Normal Ambient . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . –54 to 104(C (–65 to 220(F)
High Ambient (one hour) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177(C (350(F)
Natural Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 149(C (32 to 300(F)

WHITTAKER
DESCRIPTION PART NUMBER HAZARDOUS AREA RATING

Absolute Pressure Transducer Assembly C173255 EEx d IIB T4 Ta 120(C, Demko Certi-
fication 95D119.658

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SECTION II

SYSTEM DESCRIPTION AND OPERATION

2-1. SYSTEM OPERATION.

2-2. The fuel metering system is designed to provide the controlled flow of natural gas fuel to the engine.

2-3. After the natural gas inlet supply line and the fuel metering valve outlet lines are connected, and
the electrical connections (see Section VII) are made, natural gas is applied to the fuel metering valve gas
inlet from the facility gas supply system. Fuel flow through the fuel metering system is initiated by elec-
trically commanding the fuel metering valve to open.

2-4. The fuel metering valve is opened as necessary to control the flow of natural gas fuel to the indi-
vidual engine combustor manifolds by modulating in response to position commands received through
the motor controller from the Mark V LM Control System.

2-5. The position commands from the Mark V LM Control System are derived from many parameters
such as engine operating conditions, gas properties, gas pressures and gas temperatures. The use of
an extensive valve characteristics map and accurate position feedback, accurately provides the desired
mass flow rates of the natural gas into the individual combustor manifolds.

2-6. ABSOLUTE PRESSURE TRANSDUCER ASSEMBLY. (Refer to Figure 2-1.)

2-7. When operating the engine, gas pressure at the inlet and outlet of each fuel metering valve is moni-
tored by the an absolute pressure transducer. Each fuel metering valve has its own dedicated pressure
transducer assembly, each of which includes three or four “smart” temperature compensated digital abso-
lute pressure transducers and their corresponding electronic interface circuit cards in one explosion proof
enclosure. Depending on system upstream piping geometry, one or two transducers are provided in each
assembly for upstream pressure measurement (GP1) and two transducers are provided for redundant
downstream pressures (GP2). For systems requiring two upstream pressure transducers, Whittaker
Controls P/N C173255-1 is used. For systems requiring a single upstream transducer, Whittaker Controls
P/N C173255-2 is used. For pressure transducer characteristics and specifications, refer to Table 2-1.

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Figure 2-1. Absolute Pressure Transducer Assembly

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Table 2-1. Pressure Transducer Specifications/Characteristics

Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Digital pressure transducers and interface

electronics in explosion proof enclosure
Service Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Natural Gas (per MIL-TD-0000-1)
Pressure Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3/8-inch tube, 3 places (compression fitting)
Pressures
Calibrated . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0 to 5 170 kPa (0 to 750 psia)
Overpressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 800 kPa (2000 psia)
Accuracy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ±0.02% of full scale
Temperatures
Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . –54 to +121°C (–65 to 250(F)
Ambient (maximum) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82°C (180(F)
Electrical Data
Voltage (normal) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 VDC
Voltage Range . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 to 16 VDC
Current . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 milliamperes
Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Terminal Block (¾-inch NPT conduit entry)
Dry Weight . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17.5 kg (38.5 pounds)

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SECTION III

INSTALLATION

3-1. GENERAL.

3-2. This section contains information on installation and interfacing of the transducer assembly with the
engine and the Mark V LM Engine Control System.

3-3. PRESSURE PORTS.

3-4. The gas pressure ports are standard ¾-inch compression tube fittings in accordance the applicable
ANSI standards.

3-5. ELECTRICAL INTERFACES.

3-6. Hard wiring to terminal strips, conduit, conduit connectors.

3-7. SHIELDING.

3-8. The shields on all of the cabling must be open at the device end and tied to the shield bar at the
Mark V LM interface, or tied to a common ground at the motor controller.

3-9. CABLE ENTRIES.

3-10. All of the cable entries into the enclosure must be done using methods approved by local certifica-
tion agencies (i.e., CENELEC, CSA, FM, etc.).

3-11. CABLE WIRE SIZING.

3-12. All customer cabling conductors must be 18 AWG.

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1 MAY 1998

SECTION IV

FAULT ISOLATION

4-1. GENERAL.

4-2. This section contains specific checks required to fault isolate the transducer assembly during ser-
vice. The first step in fault isolation is to verify the electrical connections. Make sure that all of the con-
nections are secure and that there are no damaged conductors. Refer to the electrical interconnection
diagram in Section VII. If the connections are all intact, perform component fault isolation in accordance
with the following paragraphs.

4-3. PRESSURE TRANSDUCERS (GP1/GP2).

4-4. If the outputs of the redundant GP2A and GP2B transducers, or the GP1A and GP1B (where appli-
cable) inlet pressure transducers from any of the three input branches vary from each other by an amount
that exceeds the allowed limits, a fault will be registered in the Mark V LM Controller. Since these pressure
transducers are not adjustable, the fault can only be isolated to the transducer or printed circuit board.
To isolate a defective pressure transducer or printer circuit board, the following procedure should be
performed.

a. There are three or four transducer channels in each pressure transducer assembly. If the signal
of one channel is suspect, open the transducer enclosure and interchange the connector on the printed
circuit card of the suspect channel with the adjacent channel printed circuit card (i.e., if channel GP2B is
suspect, disconnect its cable from terminal P4 and reconnect it to terminal P2).

b. If the suspect signal follows to the adjacent channel, the problem has been isolated to the
pressure transducer and the pressure transducer must be replaced.

c. If the suspect signal remains on the same channel, the problem has been isolated to the printed
circuit board and the printed circuit board must be replaced.

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SECTION V

MAINTENANCE

5-1. GENERAL.

5-2. This section outlines specific repair tasks which may be required, as determined by the results of
performing fault isolation procedures. Prior to any repair action, perform the fault isolation procedures
(refer to Section IV.)

5-3. Refer to Section VII for the system electrical wiring connections table and interconnection diagram.

5-4. REPAIR TASKS.

5-5. ABSOLUTE PRESSURE TRANSDUCER ASSEMBLY (GP1/GP2).

5-6. Pressure Transducer Replacement.

5-7. Removal.

a. Disconnect the cable assembly from the pressure transducer by loosening the two connector
screws.

b. Remove the screws and washers securing the pressure transducer to the mounting block.

c. Remove and discard the packing between the pressure transducer and the mounting block.

5-8. Installation.

a. Install a new packing on the pressure port of the new pressure transducer, between the pressure
transducer and the mounting block.

b. Secure the pressure transducer to the mounting block with the screws and washers.

c. Connect the cable assembly to the pressure transducer and tighten the two attaching screws.

5-9. Circuit Board Replacement.

5-10. Removal.

a. Disconnect all (three or four) transducer cable assemblies from the circuit board.

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b. Disconnect the cables connected to the 32-pin connector. Make sure that the connector
terminations are marked on the cable, so that they can be easily reconnected during instal-
lation.

c. Remove the mounting screws securing the circuit board, and remove the circuit board from
the enclosure.

5-11. Installation.

a. Install circuit board in the enclosure and secure it with the screws and washers.

b. Connect the cables to their assigned pins of the 32 pin connector.

c. Connect the transducer cables to their assigned connectors of the circuit board.

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1 MAY 1998

SECTION VI
MAINTENANCE PARTS LIST

6-1. GENERAL.

6-2. This section identifies parts recommended for on-site maintenance of fuel metering valve. All of the
recommended items may be ordered from Whittaker Controls.

6-3. MAINTENANCE PARTS.

6-4. Table 6-1 comprises a listing of spare parts recommended for on-site maintenance support of the
fuel metering valve.

Table 6-1. Recommended Spare Parts

ITEM RECOMMENDED
NUMBER PART NUMBER DESCRIPTION QUANTITY

ABSOLUTE PRESSURE TRANSDUCER ASSEMBLY (GP1/GP2)

1 C325937-1 Transducer, Pressure 1

2 C326270-1 Circuit Board 1

3 C327371 Cable Assembly 2

4 M83248-1-010 Packing (transducer to manifold) 4

5 NAS1354C04-12 Screw (#4-40 x 0.75 inch long) (manifold 4

attaching)

6 MS35338-135 Washer, Lock (#4) (manifold attaching) 4

7 NAS1354C04-12 Screw (#4-40 x 0.75 inch long) (manifold 4

attaching)

8 C326462 Screw (circuit board attaching) 6

9 C326469 Washer, Lock (circuit board attaching) 6

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1 MAY 1998

SECTION VII

ELECTRICAL WIRING INFORMATION AND

INTERCONNECTION DIAGRAMS

7-1. GENERAL.

7-2. This section contains the electrical schematic diagram.

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Figure 7-1. Absolute Pressure Transducer Assembly

7-2