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IGV, Servos and LVDT

 cheedee ·  Sunday at 4:47 AM

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Thread Starter #1
cheedee
C Sunday at 4:47 AM

Hello team,
I am trying to calibrate the IGV on GE Frame 5, but the difference between the manual values I input and the
actual IGV position is much and difference gets bigger as I try to move the IGV to fully open i.e from (45-85
Deg)
Manual Setpoint: 45
Actual Reading on machine:45

Manual Setpoint: 65
Actual Reading on machine:50

Manual Setpoint: 85
Actual Reading on machine:55

Manual Setpoint: 105

Actual Reading on machine: 70

Manual Setpoint: 130(displays 128 on the autocal)

Actual Reading on machine:85

This is a rough description of the readings. The unit has been down for a while(approx 1 year) and we just
finished a HGPI on it, to the best of my knowledge the IGV was operating fine. We have 80bar of Hydraulic
pressure, the servo was replaced (Moog), the IGV blades have been cleaned. Please what else can be done? ,
also what is the ideal servo current and LVDT voltage (not sure if this is phrased properly) , I have uploaded the
autocal screen?

1) Type of Mark* being used = Mark V(TMR)

2) Did you perform a servo current polarity check after replacing the servo and before starting this "calibration"
procedure?=Yes
3) Have you been changing the Null Bias Current value when you have been "calibrating" the IGVs?=NO
4) What is the Null Bias Current value presently running in the Mark* right now?= ?? How can I measure this??

And one more thing:

5) What are the values of the LVDT voltages when the IGVs are fully closed (somewhere around 45 DGA, or
slightly less)? 34DGA
LVDT 1 voltage- <R> -0.306 , <S> -0.315 ,<T> -0.302
LVDT 2 voltage- <R> -0.277 , <S> -0.275 ,<T> -0.277

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CSA #2
Sunday at 12:32 PM

cheedee,

That's just a HORRIBLE screen shot--not the quality of the photo (it's okay), but the data on the AutoCalibrate
display!!!

2) Did you have the IGV servo powered by each individual processor when checking the servo current polarities?

4) You don't measure Null Bias Current; it's something that's set in the I/O Configurator, on the TCQA screen for
the respective servo valve output regulator (Number 5 in your case).

5) I'm surprised about those LVDT voltages and the angle you listed (34 DGA).

Anyway, when the IGVs are "fully closed" (which they should be when L20TV-1 is logic "0" AND the Aux. L.O.
Pump and Aux. Hyd. Pump are both running, and the Manual feature of the IGV AutoCalibrate screen is NOT
being used, the LVDT voltages should each be approximately 0.680 VAC RMS to 0.720 VAC RMS (or, 0.700 VAC
RMS, +/-0.020 VAC RMS). That is, when the LVDT actuator has moved the IGVs to the position where they can
not close any further (some kind of mechanical limit--be it the actuator or a ring stop), the IGV LVDT feedback
voltage should be approximately 0.700 VAC RMS (and it can ONLY be properly measured with a True AC RMS
voltmeter/multimeter). The voltages shown on the AutoCalibrate display are AC RMS values. On the photo you
provided, the manual reference was 128.0, and the IGV feedback calibration is basically indicating 124 (the
median of the three readings on the row labeled "Actual Position").

USUALLY, when the IGVs are "fully closed" and against some kind of mechanical limit, or mechanical stop, the
measured angle (using a machinist's protractor) is LESS THAN 34 DGA, something around 30-32 DGA or so. 34
DGA is the minimum operating angle--and one doesn't want the unit up against a mechanical limit/stop when it
is supposed to be controlling a particular angle, so the mechanical limit/stop is set to be slightly less than 34
DGA, usually two degrees or so less than the minimum operating angle).

USUALLY, when the IGVs are "fully opened" and against some kind of mechanical limit, or mechanical stop, the
measured angle (using a machinist's protractor) is MORE THAN 84 DGA, something around 85-87 DGA or so. 84
DGA is the maximum operating angle--and one doesn't want the unit up against a mechanical limit/stop when
it is supposed to be controlling a particular angle, so the mechanical limit/stop is set to be slightly more than 84
DGA, usually two degrees or so more than the maximum operating angle).

So, it would appear that the IGV LVDTs may not be properly configured to begin a calibration--with the fully
closed voltages set to approximately 0.700 VAC RMS.

When calibrating IGV LVDT feedback using AutoCalibrate, one needs to know the ACTUAL, MEASURED angle of
the IGVs when they are at the fully closed mechanical limit/stop, AND when they are at the fully open
mechanical stop/limit. And, that value has to be entered into a file named ACALIB.DAT, in the proper area.
AutoCalibrate reads the information from ACALIB.DAT and uses than when scaling the LVDT feedback. From the
photo you supplied, the values in ACALIB.DAT are 34.0 DGA and 84.0 DGA--and that's NOT what the actual
LVDT positions should be when they are fully closed and fully open, and up against mechanical limits/stops at
both ends of travel. (I'm reading the ACALIB.DAT values from the rows "Position at POS Cur Sat." and "Position
at NEG Cur Sat.".)

AutoCalibrate is "stupid"--all it can do is move the IGVs (and the IGV LVDTs) to the closed mechanical limit/stop
and then to the open mechanical limit/stop. And it needs to be TOLD what the IGV angles are at those
positions--and that is done by physically measuring the angles, usually using a machinist's protractor, and then
entering the values into ACALIB.DAT so that AutoCalibrate knows what the positions are when the IGV (and the
IGV LVDTs) are when the up against the closed- and open mechanical limits/stops.

The Null Bias Current Value for the IGVs should be 2.667. (It RARELY has to be any other value!) You find that in
the I/O Configurator. When replacing a servo valve the Null Bias Current value should ALWAYS be set to 2.667
BEFORE beginning the servo current polarity check. With a Mark* V, if one changes the Null Bias Current value in
the I/O Configurator the change has to be Saved while on the page where the change was made, then one has
to exit the I/O Configurator while saving the change, and then the change has to be downloaded to each
processor (<R>, <S> and <T>), and then each processor has to be re-booted (using the power switch in the
<PD> Power Distribution core) ONE AT A TIME.

I don't know where to start, because there's NO way the LVDT feedback should be reading 124 DGA (except for
a really out of whack AutoCalibation procedure). Something is really amiss, I'm afraid. And I don't know what is
wrong. As I said, I believe the IGV LVDT voltages at the fully closed mechanical limit/stop are not set correctly.
They have to be set by loosening the jam nuts on the cores (the LVDT rods that move into and out of the LVDT
cores) and watching the voltage of the LVDT to set it to approximately 0.700 VAC RMS when the IGV is against
the fully closed mechanical stop/limit. So, if you haven't verified those voltages, and adjusted them if necessary,
you need to start there. You don't need to do anything except make sure the IGVs are fully closed. You can do
that by just leaving AutoCalibrate completely off, making sure L20TV-1 is at logic "0", turning on the Aux. L.O.
Pump and the Aux. Hyd. Pump, and observing the IGVs and the pointer on the side of the axial compressor case.
The pointer should go to about 32-34 DGA (maybe even a little less than 32 DGA), and the IGVs should appear
to be closed (as closed as they can be). If you can see the IGV actuator, it should be holding the IGVs in the fully
closed position. (NOTE: It's pretty common for mechanics and pipe-fitters to use the IGV pointer on the side of
the axial compressor like a ladder rung, AND it's NOT common for this pointer to be properly set after a
maintenance outage. AND, it's very difficult to get a machinist's protractor into the IGVs when they are fully
closed (unless you have a properly modified ruler on the machinist's protractor). So, actually measuring the IGV
angle when the IGVs are fully closed can be difficult. It's common for the mechanics when they are finished re-
assembling the machine after an outage and are adusting the pointer to do so at several angles GREATER than
34 DGA, and the hope is that when it is set correctly for those angles it will indicate the proper angle when the
IGVs are fully closed. So, if you don't have a machinist's protractor with a modified ruler, you will probably NOT
be able to measure the IGVs when they are fully closed or at low angles. But SOMEHOW you have to try to do
some kind of verification of the IGV pointer on the side of the axial compressor case if that's all you have to
measure the IGV angle.)

It appears that some unusual values have been entered into the I/O Configurator for the "IGV LVDT #1 and #2
0% cal. ref." and IGV LVDT #1 and #2 100% cal. ref." The values in those rows are completely off, and they can
only get "off" by downloading bad values, or by an out of whack AutoCalibration procedure.) If you have been
putting 0% and 100% stroke voltage values into the I/O Configurator and then downloading them to the
processors and rebooting the processors, I hope you have copies of the values you originally found in the I/O
Configurator. And, I very strongly suggest you put those original values back into the I/O Configurator along
with a Null Bias Current value of 2.667, check the values, save them when exiting the I/O Configurator, download
them to <R>, <S> and <T>, and re-boot <R>, <S> and <T> individually. This should get the LVDT positions on
the HMI display AND in AutoCalibrate (the Actual Position) to somewhere around 32-34 DGA or so. And, this is
a good place to start. You now have the correct value of Null Bias Current, as well as some reasonable LVDT 0%
and 100% stroke voltages in EEPROM and in RAM of the TCQA cards in <R>, <S> and <T>.

I'm pretty certain I'm near to or have run up against the 10,000 character limit of the new Control.com. So, I'm
going to post this reply and continue in another post below.

 ControlsGuy25

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CSA #3
Sunday at 1:57 PM

cheedee,

So, moving on, let's sum up what's been done here to try to get to a good starting point. You have checked, and
changed if necessary, the 0% and 100% stroke voltages AND the Null Bias Current value in the I/O Configurator
and downloaded them to the three control processors and re-booted the control processors one at a time. In
addition, you have verified and adjusted the LVDT cores to achieve the 0.700 VAC RMS, +/-0.020 VAC RMS
voltages with the IGVs fully closed against the mechanical limit/stop. AND, with the IGVs against the fully closed
mechanical limit/stop, you have checked the IGV pointer to make sure it's indicating something slightly less than
34 DGA. (And if you have a proper machinist's protractor, you have actually measured the IGV angle and made a
note of that.)

When you open AutoCalibrate now, after the downloading and re-booting, you should see an "Actual Position"
value of somewhere around 32-34 DGA or so (I'm presuming the Aux. Pumps are OFF, and L20TV-1 is at logic
"0"). You should see the values of 0% and 100% stroke voltages you entered into the I/O Configurator and
downloaded to the control processors in the top of the AutoCalibrate display. If you are only using the IGV
pointer on the side of the axial compressor for IGV position indication, write down the value you see on the
pointer.

Now, you can turn on the Aux. Pumps, and you can force L20TV-1 to a logic "1" and when you do that you
should see the IGVs move a little bit (someone should be watching the IGVs, and you should see the "Actual
Position" value change to approximately 34 DGA, or so)--because the "Required Position" value should be 34
DGA AND you have hydraulic pressure AND L20TV-1 is a logic "1".

If you don't have a machinist's protactor and are going to continue to use the IGV pointer on the side of the
unit and you have some confidence it is reasonably indicating a good angle, you now need to move the IGVs to
the fully open mechanical limit/stop. To do this, you need to use the "Manual" feature of AutoCalibrate, and put
in a reference angle of approximately 95 DGA (you shouldn't need any bigger reference angle than this) and
then enable "Manual." The IGVs should move to the fully open mechanical stop/limit (the person who is
watching the IGVs at the unit should indicate they have moved, and the IGV pointer should indicate something
slightly greater than 84 DGA. As should the "Actual Position" values on the AutoCalibrate display! At this point,
you need to write down the position from the IGV pointer on the side of the axial compressor.

Change the Manual Position Reference back to something like 25 DGA and the IGVs should move to the fully
closed mechanical stop/limit, the IGV pointer should return to the value you wrote down when you started this
procedure, and the "Actual Position" values on the AutoCalibrate display should return to what they were when
you started this procedure. Disable "Manual" control of the IGVs, exit AutoCalibrate, and unforce L20TV-1 (it
should return to logic "0").

You now need to open F:\UNIT1\ACALIB.DAT and scroll to the SVO5 regulator section, and change the
POSITION_POS_SAT value to the IGV angle at the fully closed that you wrote down and verified above. And you
need to change the POSITION_NEG_SAT value to the IGV angle at the fully open position that you wrote down
above. (You can use MS-Windows Notepad to open the file and change the values, saving the changes when
you exit the file.)

POSITION_NEG_SAT 89.5
POSITION_POS_SAT 33.7

The two values above are from an OLD Frame 6B unit, and they represent the measured angles, using a
machinist's protractor, after the unit was overhauled before being shipped to a new site and installed and
commissioned. The value of 89.5 is a little "high" for the fully open position, and the value of 33.7 is a little low
for the fully closed position--but that's how the mechanical stops were set and left and that's what they had to
work with. At least they're not 34 and 84--which would be incorrect for a lot of reasons. Just put the values you
have into these two fields, save the changes and exit the file.

Now, when you open AutoCalibrate again, you should see the two values you entered into ACALIB.DAT! That's
good!

Now you can perform an AutoCalibration of the IGV LVDTs after you force L20TV-1 to a logic "1". I'm going to
guess the values at the top of the AutoCalibrate display are going to change to something like this:

<R> <S> <T>

LVDT #1 0% cal ref. -1.1008 -1.1014 -1.1001
LVDT #1 100% cal ref. 3.992 3.999 3.987
LVDT #1 0% cal ref. -1.1017 -1.1008 -1.1021
LVDT #1 100% cal ref. 3.982 3.980 3.879

AND, the "Actual Position" values will change to approximately 34.0 DGA, or very close to that.

Now, when you use "Manual" to verify the positions, you should see something very much better. (When I do
IGV LVDT verifications, I don't start from 34 DGA and go up to 84 DGA in 10 DGA increments or so. I start by
putting the IGVs at the fully open mechanical stop, but using a reference of, say, 95 DGA, (of course, the IGVs
can't actually get to 95 DGA, but that's okay for this purpose). Then I put in a reference of 84 DGA and check
and record the actual measurement, and then 74 DGA and check and record the actual measurement, then 64
DGA, and so on.) The difference between the "Actual Position" in the AutoCalibrate display (which is the scaled
LVDT feedback!) and the actual measured position (from the IGV pointer in your case) should be very small.
Also, the difference between the "Required Position" (the Manual Position Reference) and the "Actual Position"
(on the AutoCalibrate Display AND the IGV pointer indication) should be very small. Let us know if it's not.

If you are happy with the results, take a photo of the AutoCalibrate display and send it to us. The next thing you
need to do is to average the 0% and 100% stroke voltages for LVDT#1 and LVDT#2, and then open the I/O
Configurator to the IGV SVO (SVO5 on the TCQA card) and enter the average voltages for the two LVDTs, check
the values on the page, then exit the I/O Configurator and save the changes, and then use the EEPROM
Downloader to download the IOCFG partition to <R>, and <S> and <T>. THAT'S ALL YOU HAVE TO DO!!! You
don't have to re-boot the processors--because the values in RAM of <R> and <S> and <T> are "perfect" right
now. All you have done is to get the average values into EEPROM so that if something happens and someone
needs to re-boot a processor (or all three of them) they will have the average values (which isn't the "perfect"
value-but it's GE (Good Enough)) to continue to run.

That's it. That should be all you need to do. Now, I'm presuming (and this is a BIG presumption) there aren't
relevant Diagnostic Alarms that are preventing the above procedure from working correctly. I'm presuming the
servo current polarity check was done correctly. I'm presuming the mechanical stops on the IGV mechanism
were set correctly after the outage. I'm presuming the IGV pointer is reasonably accurate (if you don't have a
machinist's protractor to measure the IGV angles properly). I'm presuming the differences between "Required
Position" and "Actual Position" for each of the verification angles is small (less than 0.5 DGA, or less--hopefully).
And, I'm presuming the differences between "Actual Position" and the IGV pointer for each of the verification
angles are very small, too. If you write back with values, please provide the "Actual Position" values from the
AutoCalibrate display, AND the IGV pointer position for each angle you have an issue with.

So, I have made a few presumptions--and I've stated which ones I made. I have provided a reasonably good
procedure for setting the "zero stroke" LVDT voltages (the LVDT voltages when the IGVs are at the fully closed
mechanical stop/limit). I have provided the normal Null Bias Current value which should be used as the starting
point (and, usually, the actual value for normal operation) for LVDT calibration. I have hopefully gotten the
TCQA RAM values back to a reasonably good starting point (because I presumed you have been changing 0%
and 100% stroke voltage values in the I/O Configurator and downloading and rebooting). And, from there--
presuming no relevant Diagnostic Alarms and a reasonably accurate IGV pointer, everything should be good.

Now, if you HAVEN'T been changing I/O Configurator values and downloading and re-booting, all that is
necessary to get rid of those horrible 0% and 100% voltage values in the photo you sent is to re-boot the
control processors, one at a time. That will download the values of 0% and 100% stroke voltages from EEPROM
(something more like the examples above) and that is a good starting point.

Please write back to let us know how you fare in resolving this problem. It's important to start from a "known
good" condition, with properly verified servo currents, properly adjusted LVDT voltages when the IGVs are at the
fully closed mechanical limit/stop (that's called the "zero stroke" position for the IGVs--the fully closed
mechanical limit/stop position) and the typical normal value of Null Bias Current. If you still have issues, we can
try to help with those. BUT, if you still have problems, then there are Diagnostic Alarms which we haven't been
told about, there are error messages being reported by AutoCalibrate which we haven't been told about, or the
IGV mechanical limits/stops weren't checked/set correctly, or there's something wrong with the IGV actuator
mechanism, or the servo (I have seen a LOT of servos get replaced, and the area was not clean and the people
doing the replacement weren't using proper practices and dirt get into the servo before it was even installed--
causing a near immediate failure).

 ControlsGuy25

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Thread Starter #4

C cheedee
Monday at 3:19 AM

Thanks for this VERY IN-DEPTH reply, I'll crunch the information and get back to you with an update. I'm sure
with your help it will all be resolved

 ControlsGuy25

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Thread Starter #5

C cheedee
Monday at 9:45 AM

Hello CSA,
Thanks for the procedures, I'm still carrying them out and would get back to you with any update. I do have a
question though, I have attached Image of the IO config page, Please how do i change the Null bias in the io
config page??

CSA said: 

along with a Null Bias Current value of 2.667,

Attachments

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CSA #6
Monday at 10:18 AM

cheedee,

Click in the field for 'Current Bias' (it's 3.0 in the picture), enter 2.667 and press ENTER, then click on 'VERIFY
SCREEN' and all the field value backgrounds should return to white again; if one is purple then that one is not
being accepted by the I/O Configurator. Then click on EXIT CARD DEF, and then click on SAVE AND EXIT to get
out of the I/O Configurator. Then use the EEPROM Downloader to download IOCFG to the control processors
and then re-boot the control processors one at a time. PAY ATTENTION to the screen when downloading and
note any errors!!! Don't be in a hurry; downloading takes only a few seconds per control processor if done
correctly. Being in a hurry saves NO time and leads to all sorts of problems (usually).

 ControlsGuy25 and cheedee

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Thread Starter #7
cheedee
C Today at 3:17 AM

Hello CSA,
An update on the troubleshooting. I noticed one of the LVDTs(96TV-2) was a bit erratic(might be grounding, still
yet to establish the cause) so I opened the connection in the marshaling panel, only one LVDT connected at the
moment 96TV-1. I attempted to an autocal of the LVDT feedback and there was some improvement.

This margin of error I was getting previously ;

Manual Setpoint: 45
Actual Reading on machine:45

Manual Setpoint: 65
Actual Reading on machine:50

Manual Setpoint: 85
Actual Reading on machine:55

Manual Setpoint: 105

Actual Reading on machine: 70

Manual Setpoint: 130(displays 128 on the autocal)

Actual Reading on machine:85

has stopped, but now the values are inverted(Increasing angles on the autocal gives reducing angles on the
machine) . I am having something like this now;

Manual Setpoint:34
CSGV:34
Actual Reading on machine:85

Manual Setpoint: 40
CSGV:41.4
Actual Reading on machine:80

Manual Setpoint: 65
CSGV:66
Actual Reading on machine:60

Manual Setpoint: 75
CSGV:76.3
Actual Reading on machine: 50

Manual Setpoint: 85
Actual Reading on machine:40
CSGV:84.5

What could be the cause? The inverse polarity of the servos??,(I'll try to invert and see if it helps), I inverted the
LVDT polarity but it didnt make any difference

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 ControlsGuy25

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ControlsGuy25 #8
Today at 4:50 AM

cheedee said: 

Hello CSA,
An update on the troubleshooting. I noticed one of the LVDTs(96TV-2) was a bit erratic(might be grounding, still yet to
establish the cause) so I opened the connection in the marshaling panel, only one LVDT connected at the moment 96TV-1.
I attempted to an autocal of the LVDT feedback and there was some improvement.

This margin of error I was getting previously ;

Manual Setpoint: 45 Click to expand...

Hello All,

Cheedee,CSA,

I just have a read on a Mark5 manual and some values showed in "Regulator definition for Servo 5" are slightly
different that the ones you shared here .

For example :
Suicide position limit is set at -10 your configuration is showing -5 can you confirm?

I am not sure that it can improve the " must/correct readeable value", but you should double check with control
specification document , that the values are matching?
Also for LVDT *1&2 zero stroke, are showing "positive values" around 06.999 in the Manual Yours are "negative
values" around -0.275/-0.309.

Again only the control specs, that you got at site can give right values.

That's what I can add for the moment, I am interested to know how the final solution, is as I may be faced in
future on such troubleshooting.

Hope this can help,

ControlsGuy25.

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CSA #9
Today at 10:09 AM

cheedee,

Specifically, what about 96TV-2's output gave you cause for suspicion? WHEN did you spot this unusual output?

The LVDT #1 values at the top of the AutoCalibrate display photo you posted are very, very odd. Those values
are ones that AutoCalibrate calculates after an AutoCalibration sequence has completed. And, based on my
experience--AND the values I posted previously, they are exactly opposite of what they should be. They are even
opposite of the values in the I/O Configurator for LVDT #1.

I don't even know if "inverting" the LVDT output can cause what you are describing; I suppose it's possible, but I
have never seen it nor have I tried. The output of an LVDT is a differential voltage (as the name, Linear Variable
Differential Transducer (or Transformer)), so I guess it's possible but I'm not sure. One would have to compare
the colors of the LVDT wiring and then trace it all the way back to the Mark V I/O terminal boards to be sure it's
properly connected. And, while I've used an oscilloscope a few times when looking at LVDT voltages, but it's
confusing for most and because of the low voltages and high frequencies some 'scopes don't work very well
when trying to measure LVDTs.

So, look at the currents in the row 'Servo Current': <R>'s value is -0.22%, <S>'s value is -6.22%, and <T>'s value
is -0.29%. This is indicative of some kind of problem. AND, as you note, when you increase the Manual Position
Reference the actual reading on the IGV pointer on the axial compressor case decreases. I have to believe there
is something wrong with the currents being applied to the IGV electro-hydraulic servo valve.

I have written many, Many, MANY times on Control.com about how to perform servo current polarity
checks/testing. It's not rocket science. You use Manual positioning to put the IGVs at some mid-stroke position
and then you disconnect one of the servo output wires from the <S> Mark V output terminals and one of the
servo output wires from the <T> Mark V output (being careful NOT to ground or short the disconnected wires,
please and thank you). This leaves ONLY the servo current from <R> passing through one of the coils of the
servo. If the current is correct, the device will remain at mid-stroke (not exactly at the position it was when you
started disconnecting the <S> and <T> servo wires, but it shouldn't change by more than 2- or 3% or so). If the
device moves to one end of travel (usually the closed end) or the other end of travel under the current from
<R> only, then the current from <R> is incorrect (meaning, the wires connected from the output of <R> to the
servo coil are reversed). So, if the device did NOT remain at mid-stroke when <S> and <T> was disconnected
AND the device moved to the closed position (usually), then one has to reverse the wires from <R>'s servo-
valve output to the servo. You can do it at the Mark V <R> output terminal board, or you can do it in the JB at
the IGV actuator--doesn't matter where the wires get reversed, just reverse them ONLY in one place or the other
(not both!). Once the wires are reversed (if they were wrong), the device will return to mid-stroke and remain
there.

Next, you re-connect the <S> servo output wire at the Mark V output terminal board and disconnect one of the
<R> servo output wires. The device should remain at mid-stroke--if the current from <S> is properly connected
to the servo valve coil. If the current is the wrong polarity, the device will move very quickly from mid-stroke to
one end of travel or the other (usually closed)--indicating the current being applied is incorrect and needs to be
reversed. If you have to reverse the servo wires from <S> and the device returns to mid-stroke position, then
the current being applied is now correct.

Next, you re-connect the <T> servo output wire at the Mark V output terminal board and disconnect one of the
<S> servo output wires. The device should remain at mid-stroke--if the current from <T> is properly connected
to the servo valve coil. If it doesn't and it moves to one end of travel or the other, then the current being applied
is incorrect and it needs to be changed. Once the current from <T> is correct and the device is at mid-stroke
under the control of <T> only, then you can re-connect the other two servo output wires and the device should
remain at mid-stroke.

This is about the single most important thing when replacing a servo valve--testing the polarity of the current
passing through the servo coils. All servo coils have the same color wiring coming out of the servo coils--and
one would expect the colors would ALWAYS reflect the same operation. BUT, I've come to understand all the
colors really mean is that RED and YEL, for example, are for one coil, and always for one coil--but it does NOT
always mean that positive servo current should be connected to RED and negative servo current should be
connected to YEL for the same operation. RED and YEL just means it's one coil, and it's up to the technician
replacing the servo to verify the polarity of the servo current being applied results in the desired operation. THIS
is why a servo polarity check is so important--and doing it under the control of a single servo current as
described above--is doubly important.

If I were you, I would re-boot the three control processors one at a time. (Why? Because of those values at the
top of the AutoCalibrate display--they're just plain bass-ackwards (wrong!).) I would leave 96TV-2 disconnected-
-for now. I would then (re-)perform a servo current polarity check, to start with. I would be writing down every
step I perform (I have to believe you are under some pretty intense pressure to get this fixed, but try to put it
out of your mind, and be thoughtful and logical and write down the steps as you perform them--it seems like
it's more trouble than it's worth, but when you're under a lot of pressure and you're trying this, that and the
other thing sometimes taking the time to write things down helps to calm one's self down and eliminate missed
steps).

Once you have the servo current polarity correct (or verified to be correct if they are all correct from your
previous checks), then you can try stroking the IGVs manually to see that they move in the proper direction. The
value on the display won't match the reading on the pointer, but at this point all you're trying to do is confirm
that when you tell the IGVs to open they move in the open direction, and when you tell the IGVs to close they
move in the close direction. (I would write down the reference, the display value, and the actual value for every
move--and you should only have to try three or four positions to get a sense of whether or not they are moving
in the proper direction.)

THEN you can try an AutoCalibrate. (I'm presuming you have properly modifed ACALIB.DAT--as per what was
written above!) What should happen is this: The IGVs should first move to the fully closed mechanical limit/stop,
and then they should ramp open to the fully open mechanical limit/stop, then then should return to the fully
closed mechanical limit/stop. SOMETIMES, there is a little "bobble" at about mid-stroke when the IGVs are
ramping open and/or ramping closed--that's normal and to be expected (a little bobble). Very shortly after the
IGVs have returned to the fully closed mechanical limit/stop the values at the top of the AutoCalibrate display
for 0% and 100% stroke voltages should change. And they should be more like the ones I wrote about earlier,
and the ones in the I/O Configurator.

Once the 0% and 100% stroke voltages are correct, then you can verify the accuracy of the calibration. If the
accuracy is satisfactory, then you need to decide what to do about 96TV-2.... I presume you don't have a new
LVDT to replace it with...? I also imagine that there are several Diagnostic Alarms related to 96TV-2 being
disconnected, and probably an error or warning message or two from AutoCalibrate telling you that there's a
problem with the feedback from 96TV-2 not changing or something to that effect. It's even possible that
AutoCalibrate is not completing properly because of the missing feedback from 96TV-2 (I believe some older
versions of AutoCalibrate would behave erratically if one of the two LVDT feedbacks was missing, or was wildly
inaccurate--but I do believe you would most likely be able to finish an AutoCalibration with only one LVDT
feedback--even if you get some error or warning messages from AutoCalibrate (at the bottom of the
AutoCalibrate display. And if you DO get error or warning messages from AutoCalibrate during or after an
AutoCalibration, PLEASE POST THEM here.) I would still like to understand what it is about 96TV-2 that make
you suspect it's not working correctly, but, I'm sure you're under a lot of pressure right now and so that's not
important.

Please write back to let us know what you find! (And, PLEASE, take the time to write down what you are doing.
You will have a record of what you did to review later when you consider what happened (and you SHOULD
think about what happened later, and try to understand what happened so that it doesn't happen again in the
future!--that's the sign of a GOOD technician or engineer, someone who tries to improve the way the perform
their tasks and their job), AND, again--it does really help with reducing the stress and pressure.

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