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1、350 BAR INTERNAL SOLENOIDTANK VALVEREFERENCE MANUALTV-2XX VALVESSpecifically designed for 350 bar Hydrogen, the IMPCO GFI solenoid operated internal tank valve provides enhanced storage system safety. Available in both 12 VDC and 24 VDC models. An integrated temperature and pressure activated relief
2、 device ensures total system safety by ensuring tank protection.Note: Not all models exactly as shown.1CONFIDENTIALITYThe information contained in this document is confidential and proprietary to IMPCO Technologies Control Systems. This information cannot be disclosed to other parties without writte
3、n authorization from IMPCO Technologies. This document is intended only for customers engaged in a current confidentiality agreement with IMPCO Technologies.DISCLAIMERAlthough every effort has been made to provide complete and accurate information, IMPCO Technologies cannot guarantee performance bas
4、ed solely on this document.Table of ContentsPHYSICAL DIMENSIONS2GAS SCHEMATIC AND SPECIFICATIONS4ELECTRICAL SCHEMATIC AND SPECIFICATIONS6TEMERATURE SENSOR7OPTIONAL CONNECTOR AND MATING CONNECTOR8PRESSURE RELIEF DEVICE (PRD)9MANUAL LOCKDOWN9DIAGNOSTICS10SERVIC CHECKS14SPECIAL TOOLS15APPLICATION CONSI
5、DERATIONS162PHYSICAL DIMENSIONSThe internal tank valve is intended to fit into a standard 2-12 UN tank thread, with only 2” 50.8mm protruding beyond the neck of the tank. To keep space requirements to a minimum, all connections are radial to the tank neck. Even the manual lockdown can be accessed fr
6、om the side.Main materials in gas contact:- 6061-T6 aluminum- Glass-18-8 Stainless steel- 430F and FR Stainless steel- Nitrile- Dupont Vespel- Delrin- Copper wire, insulation- Heatshrink tubingWeight (w/o sensors): 1.925 lbs0.87 kgTank volume displaced:6.4cu. in.0.105 LInlet/Outlet ports:9/16-18 SAE
7、 J1926/1, -6 O-ringPRD Port7/16-20 UNFSAE J1926/1, -6 O-ringTank thread:2-12 UN3Minimum clearances inside the tank are given below. These are not a gland or tank design, but only designated minimum clearances.4GAS SCHEMATIC AND SPECIFICATIONSGENERALGas:HydrogenNominal pressure:5075 psi350 BargMax. o
8、verfill pressure.6350 psi438 BargMin. burst pressure:20,300 psi1400 BargOperating temperature:-40C to +85CCv, inlet to tank0.7Cv, inlet to outlet1.2FILLINGThe solenoid does not need to be powered to fill. A pressure differential of about 2 bar (30 psi) opens the solenoid. It then acts as a check val
9、ve, preventing flow back out.The high pressure sensor reads pressure near the inlet, not inside the tank. At high fill rates, it reads higher than the pressure in the tank, due to pressure losses through the valve.The temperature sensor reads the temperature of the gas inside the tank.RUNNINGEnergiz
10、e the solenoid to open the valve.The high pressure sensor reads the tank pressure.Using the manual override tool has the same effect as using the solenoid.WARNING: Use of the manual override tool will damage the solenoid piston seal and the valve must be replaced. Return the damaged valve to IMPCO T
11、echnologies.CLOSEDSimilar condition exists if the manual lockdown is used.Only the PRD is connected to tank pressure. The PRD cannot be isolated from the tank pressure.The temperature sensor still reads gas temperature.The pressure sensor is not connected to the tank and could be removed if the line
12、s are drained and the manual lockdown is closed.ELECTRICAL SCHEMATIC AND SPECIFICATIONSNominal voltage:12V24VMax. voltage:18V36VCurrent:1 ampTransient clip voltage:40VResistance19.2 +/-5% ohms 20C71.82 +/-5% 20cDielectric Strength of coil 1000VRMS1000VRMSDuty Cycle Continuous Continuous6SOLENOIDThe
13、solenoid is not polarity sensitive. A transient suppressor is installed to absorb the voltage spike that occurs when the solenoid is released. This keeps the reverse voltage spike down to 40 volts, for about 3 milliseconds. 7THERMISTORThe thermistor is on the pressure side of the valve, inside the t
14、ank. Because of this location the sensor reads the actual gas temperature at that point. However, under high flow conditions, temperature differences of over 30C have been measured between various points in the tank. This is something that must be tested in given tank setups. Sensor Supplier Specifi
15、cationsTYPENTCR25C2.7Kohms +/-2%Tolerance2%Thermal Time Constant10sThermal Dissipation2mW/CPower 25C.25WPower 85C1.25WOPTIONAL CONNECTOR AND MATING CONNECTORIMPCO Technologies can supply the tank valve (including temperature sensor) with either a 16” (40 cm) unterminated pigtail or with a standard c
16、onnector on the end of 6” (15 cm) of wire. 9PRESSURE RELIEF DEVICE (PRD)The valve is equipped with a PRD, to vent the tank in the event of a fire. When the valve is exposed to excessive heat, the PRD opens and vents the tank through the vent port. Models are available with either 103C (217F) or 109C
17、 (228F). Model numbers ending in “0”, such as TV-110 are 103C, whereas those ending in “5” are 109C. The 103C (217F) contains cadmium, which is being phased out, while the other does not. IMPCO Technologies suggests that the non-cadmium version be used unless there is a legacy reason to do otherwise
18、.The PRD is permanently connected to the interior of the valve. Because of this, it cannot be intentionally or unintentionally shut off.The PRD is capable of flowing about 200 grams per second of hydrogen, although actual flow rates will vary. The vent line should be sized to adequately handle this
19、flow, and to guide it safely away. The line must also be protected from intrusion of water or other contamination.MANUAL LOCKDOWNThe valve includes a manual lockdown for service work, which shuts off all flow into and out of the tank. The lockdown is a 1/4 hex located on the face of the valve (see p
20、age 2 for diagram). It is normally turned counterclockwise to the fully open position. By turning it clockwise to 5.4 Nm 4ft-lbs, the only flow path into and out of the valve (except the PRD) is closed. Opening the solenoid will have no effect.When any work is done on the valve or related lines, eng
21、age the manual lockdown. If any leaks are detected in the system, engage the manual lockdown.A separate tool is available to manually force the solenoid to open. This is only to be done when the solenoid has failed and is not capable of opening under power. Once the failure of the solenoid is confir
22、med, the lines into and out of the valve need to be emptied. The built-in manual lockdown is removed, and replaced with the manual override tool (see the Special Tools section). This has the same effect as activating the solenoid. This should only be done if the solenoid cannot be opened normally, a
23、s it can damage the valve.The manual override tool should be used in accordance with the “06396-T Manual Override Tool Procedures” (Document # GFIP 258) supplied with the override tool, or available from IMPCO Technologies.WARNING: Use of the manual override tool will damage the solenoid piston seal
24、 and the valve must be replaced. Return the damaged valve to IMPCO Technologies.DIAGNOSTICS10If problems with the valve are suspected, the following checks should be done. The following procedures, however, assume no other problems with the system are causing issues. These tests should be incorporat
25、ed into a system suppliers test procedures, and modified as needed for system effects.SYMPTOMS COVERED1) NO FLOW OF GAS WHEN VALVE ACTIVATED2) VALVE CONTINUES TO FAIL FUSES OR BREAKERS.3) INCORRECT OR SUSPECT TEMPERATURE READINGS.4) APPARENT INTERNAL LEAK.5) VALVE APPEARS UNABLE TO CLOSE.PROCEDURES1
26、) SYMPTOM: NO FLOW OF GAS WHEN VALVE ACTIVATED. There is no delivery of gas from the valve when the solenoid is activated. This procedure assumes that the related components in the system have either been verified or do not affect the test. Since not all possible system configurations can be conside
27、red in this document, refer to the system test procedures as appropriate. Special consideration should be placed on interactions from other valves plumbed with the valve in question. If possible, isolate the valve in question from others.1. Is the manual shutoff is in the open position?-Yes: Continu
28、e to step #2.-No: Open manual shutoff valve.2. Verify 12v or 24v signal sent from vehicle.Probe the solenoid supply terminals of the vehicle-side connector with a voltmeter when a signal is expected from the vehicle. Although vehicle connectors and wires will differ, they should correspond to the wh
29、ite (12v models) or orange wires (24v models). Does it read 12 or 24 volts (as appropriate for vehicle) when expected?-Yes: Continue to step 3.-No: Diagnose vehicle problem3.Verify resistance of valve connectors.Probe the solenoid pins of the valve connector with an ohmmeter. Depending on the voltag
30、e, these will either be orange or white. Resistance should be:-10-15 ohms lead to lead for a 12v coil or-40-60 ohms lead to lead for a 24v coil Valve and connector resistance correct, go to #4-lower than above values Probable solenoid short. Vent the tank using the manual override procedure and remo
31、ve the valve per system supplier instructions and return to vendor.-Higher than above values: Verify the connector and wires have no obvious failures. If possible, remove wires from connector and verify again at terminals. Unless obvious problems can be found in the connector or wires, there is a pr
32、obable valve failure. Vent tank using manual override procedure and remove valve per system supplier instructions and return to vendor.114.Verify resistance from the solenoid leads to the valve body with an ohmmeter. Ensure that the meter leads are not touching anything but the connector and body, i
33、ncluding fingers.-Greater than 1Mohm, or “open line”: Correct, continue to step #5.-Less than 1Mohm Probable valve failure. Vent the tank using the manual override procedure and remove the valve per system supplier instructions and return to vendor5.Valve activation test.This test must only be done
34、when the valve is in a condition that opening of the valve will not cause a hazardous condition! This must be ensured according to the system suppliers procedures. If possible, a known good pressure gauge or sensor should be connected downstream of the valve without any unproven valves or other devi
35、ces interfering with its function. Apply 12 or 24 volts to the valve (as appropriate for the model) from a known good power supply or battery, while listening for a clicking noise.-click is heard or pressure rises downstream Normal function, no problem with valve.-No noise, and no rise in pressure.
36、Probable failure of valve. Vent the tank using the manual override procedure and remove the valve per system supplier instructions and return to vendor-Clicking noise, but no pressure rise. Ensure the tank is actually filled and that no other factors outside the valve are causing false readings. If
37、nothing can be found, vent the tank using the manual override procedure and remove the valve per system supplier instructions and return to vendor.2) SYMPTOM: VALVE CONTINUES TO FAIL FUSES OR BREAKERS. The fuse or breaker protecting the valve or valves frequently or constantly trips.1.Verify problem
38、 is with valves.Disconnect all valves and replace the fuse or reset the breaker. Power the solenoid supply in the normal manner, per system or vehicle procedures.-Fuse/breaker still trips. Vehicle or system problem-Fuse/breaker does not trip. Continue to step 2.2.Reconnect valves.Connect each valve
39、in turn, and apply power. -Fuse/breaker trips Probable problem with that valve. Perform tests starting at step 2 of symptom 1.-Fuse/breaker does not trip. No trouble found. Problem may be intermittent.123) SYMPTON: INCORRECT OR SUSPECT TEMPERATURE READINGS. The vehicle is getting readings from the t
40、emperature sensor that are thought to be incorrect. The procedure below should work for most vehicle electronics, but steps 1 and 2 may differ on some vehicles.1. Verify the supply to the sensor.Disconnect the harness from the vehicle. Measure the voltage across the +5v and ground supply. Pinout and
41、 wire color depends on vehicle connector and harness, but +5v should correspond to the valves red wire, and 0V to the valves black wire.-reads +5v, within vehicles tolerance. Voltage is correct, continue to step 2.-reads slightly different than +5v Possible vehicle voltage variation may lead to sens
42、or reading variation, depending on vehicle electronics. This may or may not lead to a problem.-reads drastically different than +5v. Vehicle power supply or harness issues.2. Verify signal voltage.Connect +5v and ground to the red and black terminals of the valve connector. This can be accomplished
43、by using jumpers or an intermediate connector to connect the valve connector to the vehicle harness, or by removing the signal terminal from either connector and connecting normally. Read the voltage between the sensor signal (green wire on valve) and ground (black wire). See the temperature sensor
44、section of the manual for the voltage/temperature equation.-approximately 1.9 volts, depending on temperature. 0.4-3.4 can be expected over the operating range. Correct voltage. No problem with valve. If problem persists, investigate vehicle for problems, or check for an intermittent problem.- value
45、s other than expected. Probable valve failure. If possible, remove wires from connector and verify again at terminals. Unless obvious problems can be found in the connector, there is a probable valve failure. Remove the valve per system supplier instructions and return the valve to the vendor.4) SYM
46、PTON: APPARENT INTERNAL LEAK. The pressure in the inlet/outlet line appears to rise, despite the valve being de-energized.Since leak testing is very dependant on the system configuration, verify the valve according to the system suppliers instructions. The manual shutoff can be used to isolate valves to aid in diagnosing. If trouble is found, remove the valve according to the system suppliers instructions, and return the valve to the vendor.5) SYMPTOM: VALVE APPEARS UNABLE TO CLOSE. The pressure in the lines s