SERVICE BULLETIN

NOTICE: The Type of Change and Recommended Compliance specified reflects Solar’s best judgment regarding the
Service Bulletin. All questions should be directed to your Solar Field Service Representative. Solar, Saturn,
Centaur, Taurus, Mercury, Mars, Titan, SoLoNOx, and Turbotronic are trademarks of Solar Turbines Incorporated.
Cat and Caterpillar are trademarks of Caterpillar Inc. Specifications subject to change without notice.

NUMBER: 8.6/106
ISSUED: May 1999
REVISED:
PRODUCT: Mars
MODEL(S): All
Specifics:

SUBJECT: INLET GUIDE VANE ADJUSTMENTS

Type of Change: Product Improvements

Recommended
Compliance: Operation and Information

Purpose:
– To supply simple look up tables with optimum Inlet Guide Vane (IGV) settings.
– To publish revised adjustment procedures for Mars Inlet Guide Vanes.

GENERAL INFORMATION:

Summary:
The Inlet Guide Vane (IGV) and the variable stator stages of the air compressor in a gas turbine
must be positioned along an optimum schedule.

The correct adjustment of these vanes is especially important on Mars T13000 and T15000 en-
gines. The IGV and variable compressor stator stages on these turbines not only transfer during
start up (surge avoidance), but also continuously modulate during normal engine operation. Vary-
ing IGV/stator settings optimize the turbine power and efficiency under all operating conditions.

It is mandatory to calibrate the IGV and variable stator position and the associated electro-hydraulic
actuators when the engine is first installed or exchanged. After that, correct operation of the variable
IGV system should be periodically confirmed and the calibration checked annually.

SERVICE BULLETIN Page 1 of 21

NUMBER: 8.6/106
This Service Bulletin contains simple graphs and tables for periodic observation of the IGV position
and detailed adjustment procedures for the yearly inspection.

Discussion:
The Inlet Guide Vanes and the first five rows of stator blades in the Mars air compressor are ad-
justable to regulate the flow of air into the turbine.

Lever arms attached to each blade are connected to six operating rings, one for each stage. The
individual rings are interconnected with two accouter levers so that they all rotate in a fixed rela-
tionship.

The movement of all five rows of variable stators is referenced to the position of the IGV. All fur-
ther procedures mentioned in this Service Bulletin speak about IGV settings only, but they always
include and affect the next five stator stages in a similar way.

IGV Adjustment:
IGV require two major adjustments:

– The relative position between the different stator stages was adjusted during engine
assembly and should not need further correction.
– The maximum full-open IGV position varies from turbine to turbine and is determined
during test. The individual maximum IGV setting is stenciled onto the engine name tag and
onto the actuator arm at the right side of the air compressor (looking into the turbine output
shaft). A small pointer attached to the same actuator arm indicates the true IGV angle on a
scale.

Differences In IGV Operation:

The IGV operation is different between earlier and newer Mars Turbines:

– Early mars turbines including T12000 and T14000

The IGV are closed during turbine light off and acceleration to prevent air compressor surge.
During operation at high speeds, the IGV are fully open against a fixed maximum stop.
On a hot day, a fully loaded turbine operates on temperature control and the gas producer
speed (NGP ) starts to decrease. The IGV however remain fully open.
– Mars T13000 and T15000 turbines
The turbine IGV not only move during start up (surge avoidance), but also modulate
continuously during normal operation. By varying the IGV position and regulating the
compressor air flow, the relationship between NGP, air mass flow and turbine firing
temperature (TRIT) can be optimized over a wide range of ambient conditions. For peak

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NUMBER: 8.6/106
 power and efficiency at elevated ambient temperatures, the IGV remain partially closed to
keep the gas producer speed (NGP ) near its maximum (103.6%).
The PLC control system continuously calculates an optimum position for the IGV (Guide
Vane Angle Schedule or GVANG_SCH) based on ambient temperature and the measured
engine speed. This ideal IGV position is converted into an electrical control signal and sent
to the IGV actuators. For accurate operation, it is imperative that this electrical signal is
correctly transposed into the corresponding mechanical position of the IGV actuators and
the actual IGV.

NOTE
A few selected T13000/T15000 Mars generator sets in the USA do not use
pre-programmed IGV schedules, but include an additional control loop in the
PLC. As long as the turbine runs at full load, the control system continually
varies the IGV angle to keep NGP near its maximum regardless of ambient
temperature.

Though the system operates successfully, it is not a standard design and is

not covered in this Service Bulletin.

Variations in IGV Actuator Systems:

Two main IGV actuator systems are in use on Mars turbines (see also SB 6.9/100):

– Moog Actuator with Internal Position Feedback:

"Moog" actuators are bright yellow. They operate with a servo oil pressure of 1000 PSI (70
bar) and are mainly used on older Mars turbines with fixed open IGV positions. However,
new and up rated T13000 / T15000 turbines exist with use this accouter system.
Due to the active position feed back, these actuators operate very accurately and are
well suited for Mars engines with continuously varying IGV systems. However, "Moog"
actuators do not carry a "Cenelec" approval and are not acceptable to some customers.
– Tactair Electro-Hydraulic Actuator:
Old style actuators (P/N 186159-7, single coil) and new style actuators (P/N 186159-36,
dual coil) can be found in the field.
The actuators operate with a servo oil pressure of 500 PSI (35 bar) and depend on an
"open loop" set point from the control system without external feed back. The "accouter"
is actually just a positioning device and for "muscle" depends on slave cylinders at the end
of each accouter arm.

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NUMBER: 8.6/106
 Most newer Mars turbines are equipped with these "actuators". Due to their dual certification
(CSA and Cenelec), they can be used in any application.

ACTION REQUIRED

Periodic Inspection
Periodically observe the actual IGV position during turbine operation. On most packages, the
guide vane angle can be read through a window in the IGV cover on the right side of the turbine. If
not visible, the right half of the IGV covers must be removed. When properly equipped to handle
hot machinery parts (long sleeve coverall or shirt, safety glasses, leather gloves), this cover can be
removed while the turbine is running (lock out fire extinguishing system).

Failure to use proper protection can cause injury

1) CALCULATE NGP CORR:

All ideal IGV schedules are referenced against corrected gas producer speed (NGP corr). This value
is the actual gas producer speed (NGP or NGP act) normalized to 59F (15C) ambient temperature.
Though the value is computed in the PLC logic and can be read with a programming terminal, it
should be calculated manually to exclude possible errors in the PLC program.

The corrected gas producer speed(NGP corr or NGP_corr) must be used

to obtain the ideal IGV angle. Do not use the actual gas producer speed
from the display screen.

Procedure:
– Stabilize turbine at a suitable operating point.
– Measure the ambient temperature near the air inlet (T1). The Celsius or the Fahrenheit scale
may be used.
– Read the actual gas producer speed of the running engine (NGP act).
– Calculate NGP corr based on the following formula:

%NGP corr = %NpGP act

2
where:

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NUMBER: 8.6/106
 0 1
T1 + 460
2= Deg:F

519

or:
0 1
T1 + 273
2= Deg:C

288

The correction factor “Theta” (2) is the ratio of the actual air inlet temperature to the base temper-
ature (59F; 15C)’ measured one absolute scale (deg. R or deg.K).

2) CHECK IGV OPERATION AT ENGINE SPEEDS BELOW 90% NGP:

During operation below 80% corrected gas producer speed, the IGV on all Mars turbines are fully
closed to avoid air compressor surge. During acceleration between 80 and 94% NGP corr, the IGV
move proportionally from the fully closed to a fully open (or nearly open) position.

– Early Mars turbines including T12000 and T14000 have fixed full-open IGV positions
In these turbines, the IGV are used for "surge avoidance" only. Adjustment tolerances are
large (± 3.75, see table below) and rarely need correction. As long as an engine accelerates
smoothly through the 80% to 90% NGPspeed range on a cold day, surge avoidance is
maintained and no corrections are required.

Table 1 IGV settings for Mars engines with fixed full-open IGV positions:
NGP corr IGV angle Tolerance for surge
avoidance only

0% to 80.0% -45.0
82.0% -37.5
84.0% -30.0
86.0% -22.5 ± 3.75
88.0% -15.0
90.0% -7.5
92.0% 0
94.0% +7.5

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NUMBER: 8.6/106
 NOTE
Due to the individual full-open maximum setting (hard stop), not all engines
will reach the zero or +7.5 IGV position.

– T 13000 and T 15000 Mars turbines

These engines are equipped with continuously varying IGV. To judge the correct IGV
operation, follow the table under "Adjustments and Yearly Calibration" (step 1.20).
Though the basic IGV calibration in the 80 to 90% speed range is identical to Mars turbines
with fixed full-open IGV positions, tighter tolerances are used on these packages and the
tabulated IGV angles may not be correct at speeds above 89% NGP corr.

3) CONFIRM CORRECT IGV OPERATION AT HIGHER GAS PRODUCER SPEEDS.

Though turbines can operate indefinitely in the "surge avoidance" speed range, most customers
operate their engines at higher speeds and loads in the most efficient operating range.

The following IGV positions should be observed when operating a Mars turbine above 90 to 92%
NGP corr:

– Mars engines with fixed full-open IGV settings:

Somewhere between 91% and 94% NGP corr, these engines reach their fully open IGV
position. The actual threshold depends on the maximum IGV setting of an individual
machine. At all speeds above this threshold, the IGV are fully open and the accouter arms
rest firmly against the stroke limiting stop screws. The correct full-open IGV setting is
stenciled onto the name tag and onto the right IGV accouter arm. Verify IGV position via
the inspection window in the cover.
– Mars T 13000 and T 15000:
The IGV modulate even in this high speed range (Called "Normal Operating Range" in
Figure 1). The optimal IGV angle is a function of NGP and ambient temperature. Due to the
varying maximum open IGV settings on each machine, the ideal IGV schedule cannot be
listed in absolute angles. Figure 1 plots the optimum IGV position as an angle below the
individual maximum open setting.

NOTE
The tolerances for the “Surge Avoidance” line in Figure 1 Are large and
Figure 1 should only be used to judge the IGV operation in the “Normal Op-
erating Range”.

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NUMBER: 8.6/106
 Figure 1 MARS T13000 & T15000 variable IGV schedule

– Stabilize turbine between 92% NGP and full load. Full load is required at ambient
temperatures above 59F (15C). The lower gas producer speeds should be used with
cold ambient temperatures.
– Calculate NGP corr for the current operating condition. For best accuracy, NGP corr should
be between 99 and 103%. Change NGP setting if required and repeat calculation.
– Observe and measure the clearance between the IGV accouter arm and the maximum
stop screw. Compare the clearance with the IGV angle scale on the air compressor
housing and judge the corresponding angle.
– Consult Figure 1 for the ideal IGV angle (plotted as angle below the maximum
mechanical open stop) and compare. The actual IGV angle measured should be within
±1.0 of the nominal value.

NOTE
For mechanical reasons, the maximum Gas Producer Speed is limited to
103.6% NGP (uncorrected) on all Mars turbines. At ambient temperatures

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NUMBER: 8.6/106
 above 59F (15C), Mars T13000 and T15000 turbines with correctly ad-
justed Inlet Guide Vanes never reach their mechanical maximum IGV stop.

4) TRANSFER FROM "SURGE AVOIDANCE" TO "NORMAL

OPERATING SPEED RANGE"
(Mars T13000 and T15000 only)
Somewhere between 89% and 92% NGP corr, the "Normal Operating Range" IGV schedule inter-
sects with the "Surge Avoidance" curve and limits further IGV opening. Above this threshold, the
IGV modulate based on the "Normal Operating Range" schedule in Figure 1. The two IGV operat-
ing schedules are based on different parameters and the actual threshold speed varies considerably
from engine to engine.

ADJUSTMENTS AND YEARLY CALIBRATION

IGV adjustment procedures differ depending on your control system, your engine and the IGV
actuators used. Though the relative relationship (rigging) between the IGV and the five remain-
ing variable stator stages does not require periodic adjustment, it is good practice to confirm the
integrity of the torque paint on all turnbuckles and individual stator vanes before attempting any
accouter adjustments.

– Mars Engines with fixed full-open IGV settings

All older packages with relay logic or Turbotronic 1 PLC systems fall into this group. The
IGV are used for surge avoidance and only move during low speed operation (see table
under "Periodic Inspection"). After initial set up, little or no maintenance is required on the
IGV due to the relatively large tolerances. If corrections are necessary, similar procedures
as given for Mars T13000 and T15000 engines can be used.
– Mars T13000 and T15000
Packages containing turbines with continuously varying IGV require PLC controls
(Turbotronic 2 or higher) to store and execute the IGV schedule. Access to the PLC logic
is mandatory to perform this calibration.

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NUMBER: 8.6/106
 The procedures described in this Service Bulletin require temporary
changes in the control logic. The Service Bulletin assumes the use of
a standard "Allen-Bradley" control system. The Bulletin does not ex-
plain how to access the PLC logic and how to use a "Programming Ter-
minal". Instructions to change the control logic are generic descrip-
tions only, since methods and logic addresses differ between cus-
tomers.

If you are not thoroughly familiar with programming your PLC, do not
attempt to calibrate the IGV yourself. Contact Solar Customer Services
for assistance!

Basic Requirements:
– Programming Terminal and the necessary software to access the control logic.
– Hydraulic servo oil pressure must be available to operate the actuators. If the package is not
equipped with electric motor driven servo pumps, test cranking of the engine is required
during IGV adjustments.

Procedures:
1.) "Tactair" Electro-Hydraulic Actuators
1.1) Determine the full-open IGV setting for your particular engine (stenciled onto
the accouter arm). By design, a +2.5 IGV angle is considered nominal and is used
as base value in the control calculations. The correction factor GVAG_OFFST is
zero at this angle.
Calculate the "offset" Kval (GVAG_OFFST) for your specific engine by subtract-
ing 2.5 from the full-pen IGV value stenciled onto the accouter arm and the name
tag. Record correct value for GVAG_OFFST.
1.2) Attach a programming terminal to the PLC.
1.3) Confirm the following programming constants in the logic (Kvals). Correct
values if necessary and note discrepancy:
GVAG_CLLM -45.0
GVANG_INTM -4.0
GVANG_INTH -2.0
GVAG_FULOP 2.5
GVAG_OFFST (IGV STOP minus 2.5; see above)

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NUMBER: 8.6/106
 1.4) Operate engine until oil tank / header temperature stabilizes (1 hour).
1.5) Obtain T1 and NGP act and manually calculate the corrected Gas Producer
Speed NGP corr (see "Periodic Inspection"). Observe NGP corr calculated by the
control logic (NGP_CORR) and compare.

NOTE
The ambient correction factor 2 is used to calculate NGP corr (NGP_CORR).
Cases have been found where the control program does not correctly com-
pute "Theta" (2). Theta always corrects the ambient temperature to 59F.
The value in the denominator must be 519 (460 + 59) and is not a second
variable (eg T1 MATCH SET POINT or HSTDAY_TP). Correct problem if
found!

1.6) Shut down engine and remove IGV covers.

1.7) Lock out fuel system and tag all valves with "Do not operate" signs.
1.8) In the control logic, temporarily disable the rung which moves the calculated
IGV set point (GVDRV_CNT) to the "guide vane drive output" (GV_DRIVE).
In case of Allen-Bradley controls, this equates to inserting an AFI (Always False
Instruction) before the MOV (Move) command.
1.9) Change "Kval" GVAG_OFFST to a value of 4.0 for the duration of this
procedure. Record original value if not already noted in step 1.1).

NOTE
The increased value for GVAG_OFFST moves the "normal operating range"
IGV schedule upwards and out of the way. This guarantees, that the IGV
control uses the desired "surge avoidance" curve during the test run in step
1.20 (up to at least 92% NGPcorr or an IGV angle of zero).

1.10) Operate servo oil pump. Test crank turbine if your package is not equipped
with an electrical servo oil pump.
1.11) Open the IGV wide by sending a 20.0 mA signal to the IGV accouter:
Go to the "output address data table" in your programming terminal. Find the
"guide vane drive output" (GV_DRIVE). Manually enter the maximum value of
4095 (bits).

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 NOTE
The analog output card in the PLC converts the binary number in
GV_DRIVE into a corresponding 4 - 20 mA signal (4095 bits = 20.0 mA).

1.12) Confirm that the IGV accouter arm rests firmly against the maximum stop
screws. and that the stop screw setting ins not altered (torque paint). Make sure, that
the actual IGV setting obtained corresponds to the value stenciled on the accouter
arm.
1.13) Set the IGV to mid range (-22.5) by sending a 12.0 mA signal to the guide
vane accouter:
Manually enter 2000 counts (bits) into GV_DRIVE in the "output address data
table". Follow up immediately and enter 2048 counts (1/2 of 4095, rounded to the
next Integer).

NOTE
The two-step approach minimizes the influence of accouter hysteresis and
ensures that the IGV approach their mid position while moving from closed
to open (accouter retracting).

1.14) Adjust the guide vane accouter feedback turnbuckle (long turnbuckle on left
side of turbine) as necessary to obtain an IGV angle of -22.5 (see scale and pointer
on accouter arm). Ensure, that the alignment holes on the accouter arm (scale side
only) are lined up and that the alignment pin can be inserted freely. Do not insert
pin permanently!
1.15) Manually insert 850, then 903 bits into GV_DRIVE (output address data
table). 903 bits is the theoretical value for an IGV angle of -40.0. Vary the number
of bits in the data table until the IGV angle reads -40.0 on the accouter arm scale
(higher numbers will drive the IGV towards the open position). Record final value
as C- 40.

NOTE
To minimize the influence of hysteresis, always move the IGV in the same
direction, eg. from fully closed to fully open (increasing GV_DRIVE values).
If, during testing, you have to insert a lower number than the previous one,
first enter a value 50 to 80 counts below your new estimate, then type in
the estimated value.

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NUMBER: 8.6/106
 1.16) Insert 2800, then 2866 bits into GV_DRIVE to drive the IGV to a theoretical
position of -10.0. Vary number until correct position is reached (scale). Observe
above note regarding hysteresis. Record correct final bit value as C- 10.
1.17) Extrapolate the established control line and calculate the number of bits
required to drive the IGV to Zero Degrees (C0):
(theoretical value is 3520 counts, use for comparison only)
C0 = (C-10 - C-40) x 1.333 + C-40
– Round C0 to the next integer
– Insert C0 into the program "Kval" table as ZDEGDR_CNT

NOTE
– The indirect way to determine ZDEGDR_CNT is necessary, since some
engines have negative maximum open IGV settings and cannot reach
zero degrees.
– On engines with positive "full-open" IGV settings, the correct value
of ZDEGDR_CNT can be confirmed by inserting C0 into GV_DRIVE
(output address data table). Observe the actual IGV arm position (servo
oil pump still running or engine cranking). IGV position should be at
zero. Adjust ZDEGDR_CNT if required, to obtain zero degree IGV
position.

1.18) Stop servo oil pump or engine cranking. Restore automatic operation of IGV
system (GV_DRIVE) by removing the AFI instruction in the PLC logic installed
in step 1.8). Do not yet reset the Kval GVAG_OFFST to its original value.
1.19) Unlock and re-activate fuel system.
1.20) Operate engine. Confirm normal operating temperature in lube oil header
and tank. Vary engine speed and verify correct IGV operation. Be sure to read
each IGV angle during engine acceleration and deceleration. Readings should not
vary more than ±1.0.
NGP corr IGV angle Tolerance

92.0% 0
90.0% -7.5
86.0% -22.5
82.0% -37.5
80.0% -45.0 ±1.0

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NUMBER: 8.6/106
 NGP corr IGV angle Tolerance

82.0% -37.5
86.0% -22.5
90.0% -7.5
92.0% 0

NOTE
– Due to a negative maximum IGV setting, some engines will not reach
zero degree IGV.
– IGV angles above 92% NGP corr follow a different schedule and must not
be used in this comparison.

1.21) Stop engine and exchange any old style electro-hydraulic accouter (P/N
186159-7) with a new "dual coil" accouter (P/N 186159-36), if readings obtained
at identical gas producer speeds are not within ±1.0 (excessive hysteresis, see
Service Bulletin 6.9/100 for further information). Repeat procedure after exchange.
1.22) Stop engine when calibration and adjustment are satisfactory. Re-install IGV
covers.
1.23) Reset Kval GVAG_OFFST to its original value as recorded in step 1.1).
1.24) Update drawings with new Kvals and back up PLC Ladder files.
1.25) Operate equipment and wait for lube oil temperatures to stabilize. Observe
correct operation of IGV. Use Figure 1 to confirm correct IGV operation.
2.) Turbine with "Moog" Actuators
The active IGV control system using "Moog" actuators with position feedback works
with a ± 3.6 VDC signal for an IGV angle change from -45 to 0. In Solar’s standard
lay- out, +3.6 VDC represents an IGV angle of -45; -3.6 VDC represents 0.

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NUMBER: 8.6/106
 Modified control systems exist on older packages using Moog actua-
tors and fixed full-open IGV settings. The control signal has been re-
versed on these systems, using -3.6 VDC to represent an IGV angle of
-45; +3.6 VDC for 0. Though it is possible to adapt the following pro-
cedure, it is recommended that these control systems be converted
to the standard lay-out, if a turbine with continuously variable guide
vanes is retrofitted.

2.1) Perform steps 1.1) to 1.5) from calibration procedure with "Tactair" actuators.
2.2) Record the following Kvals from your logic. Standard values used are
indicated for information only. Do not correct values at this stage.
IDENT. DESCRIPTION VALUE
GVPSTNIPGN GUIDE VANE POSITION 1.0
GAIN CORR
GVPSIPOFST GUIDE VANE POSITION 0
OFFSET CORR
PTOVRDSLPE NPT GUIDE VANE 1.67
OVERRIDE GAIN
GVCLOSELMT GUIDE VANE CLOSE 3.8
LIMIT
GVOPENLMT GUIDE VANE OPEN LIMIT -4.4
GVDRIVGAIN GUIDE VANE CONTROL 2.5
GAIN
GVDRIVOFST GUIDE VANE DRIVE -0.75
OFFSET
GVCLTSTLVL GUIDE VANE CLOSE 2.9
TEST LEVEL

2.3) Measure position feed back voltage from "Moog" actuators (Vact):
Attach a Voltmeter to terminals 7 & 8 of the "Guide Vane Signal Conditioner"
Z339 and observe the LVDT feed back signal (terminal 7 is positive).
Vary engine speed to obtain the following IGV angles and record the feed back
signal (Vact). The actual gas producer speed required to achieve the desired angle
is not critical at this stage. Compare readings with nominal feedback voltage.

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NUMBER: 8.6/106
 IGV angle Feedback Nominal Tolerance
measured Feedback acceptable
Vact (VDC) (VDC)
- 45.0 + 3.6

- 40.0 + 2.8
- 22.5 0 ± 0.2 VDC

- 5.0 - 2.8
0 - 3.6

NOTE
– Due to a negative maximum IGV setting, some engines will not reach
zero degree IGV.
– The voltages measured are position feedback signals. It does not matter
whether or not the IGV accouter arms touch the minimum stop screw.

2.4) Judge severity of the calibration required:

– If the actual Voltages measured in step 2.3) are within ± 0.2 VDC of the nominal
values, the IGV actuators do not require a full calibration. The feed back signal
can be "normalized" with Kvals. Proceed to step 2.13) to continue calibration.
– Adjust "Guide Vane Signal Conditioner" box Z339 if signals are not within
tolerance specified. Continue procedure with step 2.5).
2.5) Lock out fuel and start system! Tag valves and electrical breakers.
2.6) Remove the IGV accouter with the active internal position feedback (LVDT
transducer) from the package. Though both IGV actuators are identical, only the
feed back from the left hand side accouter (opposite the IGV angle scale) is used.
Catch leaking oil from the accouter. Protect (cap) package servo oil supply and
return lines. Reconnect electric wires to the LVDT if they were removed during
accouter removal.
2.7) Manually move the accouter to its fully retracted position. Record voltage
reading between terminals 7 & 8 on "Guide Vane Signal Conditioner" Z339 (should
be a negative voltage). Mark piston position with a felt pen.
2.8) Fully extended accouter. Measure piston travel. Nominal travel is 4.64" (118
mm). Record voltage reading (should be positive). Mark full open position and
mid position (2.32"; 59 mm) with a felt pen.

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NUMBER: 8.6/106
 2.9) Move accouter to mid position and check feedback signal. LVDT signal should
be 0 ± 0.1 VDC. If not, adjust "Zero offset" potentiometer on "Guide Vane Signal
Conditioner" Z339.
2.10) Extend and retract accouter to minimum and maximum stroke and check
feed back signal. LVDT feed back signal should be ± 5.0 ± 0.1 VDC (fully
retracted = negative signal). Adjust "Output adjust" (gain) on "Guide Vane Signal
Conditioner" Z339. It is important that the minimum and maximum voltage
readings are equal values of opposite polarity. Trim "Zero offset" if required.

NOTE
Some "Guide Vane Signal Conditioner" boxes Z339 may not be adjustable
to ± 5.0 VDC. Adjust box Z339 to the maximum voltage possible so that both
readings still have equal values of opposite polarity. "Kvals" are adjusted
later to amplify the signal if necessary (step 2.15).

2.11) Repeat steps 2.7) to 2.10) until correct.

2.12) Re-install accouter and reconnect hydraulic lines. Do not reinstall the IGV
covers at this stage.
2.13) Change Kval GVAG_OFFST to 4.0 for the duration of this procedure. Make
sure that original value was recorded in step 1.1).

NOTE
The increased value for GVAG_OFFST moves the "normal operating range"
IGV schedule upwards and out of the way. This guarantees, that the IGV
control uses the desired "surge avoidance" curve during the test run in step
2.22) (up to at least 92% NGP corr or an IGV angle of zero).

2.14) Supply hydraulic pressure to IGV actuators:

– Lock out and tag fuel system if not already done so. Crank engine with crank
switch. Guide vanes should open fully.
Or:
– Run the electric servo oil pump if so equipped. Lock out fuel system and start
system in this case. Tag breakers and valves.

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 NOTE
It is important to lock out the start system if an electric servo oil pump is
used! The crank switch must be activated in the next step to energize certain
control loops.

2.15) "Normalize" the LVDT feed back signal from Z339. A slight amplification
of the LVDT feed back signal (Vact) is required in most cases. The control system
expects a voltage change from +3.60 to -3.60 VDC (Vcorr) when the IGV move
from - 45 to 0. However, the actual feed back signal (Vact) from correctly adjusted
LVDT changes only from +3.55 to -3.55 VDC. Sometimes, not even these values
can be reached.
2.15.1) Turn test crank switch "on" if not already done so. This activates
the Kval GVOPENLMT (GUIDE VANE OPEN LIMIT) and overrides
the original "guide vane position schedule" (GVPSTN_SCH). The
standard value in GVOPENLMT is -4.4 and the IGV open wide. "Kval"
GVOPENLMT can now be changed to force the IGV to any position desired
(+3.60 assumes -45, -3.60 assumes zero).
2.15.2) Change Kval GVOPENLMT to +3.70. This forces the IGV against
the -45 fully closed stop screws. Slowly decease GVOPENLMT in small
steps until the IGV reach -40.0. Record value as V-40. (Nominal value is
+2.80).

NOTE
Observe earlier notes regarding hysteresis. Always move accouter in the
same direction when testing (eg. move IGV from a closed to a more open
position. This requires increasing IGV angles and decreasing Kval in
GVOPENLMT. Observe negative numbers!).

If actuators must be moved in the opposite direction, first enter a number

about 0.3 above your new estimate and slowly decrease the number again.

2.15.3) Change Kval GVOPENLMT to -2.50. Actual IGV angle read should
be between -10 and -5. Slowly decrease number (make GVOPENLMT
more negative) until the IGV angle reads -5. Record value as V-5. (Nominal
value is -2.80).

NOTE
IGV angles of -45 and zero would be better as calibration points, but cannot
be used. Not all engines reach zero degree and the -45 IGV angle is difficult
to control due to the mechanical minimum stop.

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 2.15.4) Calculate amplification required (a). Enter "a" as "Kval"
GVPSTNIPGN (GUIDE VANE POSITION GAIN CORR) into the control
logic.

5:6
a =
(V040 0 V 05 )

2.15.5) Calculate necessary offset correction (b). Enter "b" as Kval

GVPSIPOFST (GUIDE VANE POSITION OFFSET CORR) into the
control logic.

b =
0( 040
V + V 05 )
2

2.15.6) The PLC uses "a" and "b" to correct the position feedback received
(Vact) to a normalized value (Vcorr). The normalized number is stored as
"GVPOSITION" and is used in the IGV control loop:

V corr = a 2(V act ) + b

2.15.7) Example:

V040 = +2:80
V05 = 02 60 :

5:6
a =
(2:80 0 (02 60)) :

5:6
=
5:40
= 1:0370

b =
0 (2 80 : + ( 02 60)) :

=
0 (+0 20) :

2
= 00 10 :

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NUMBER: 8.6/106
 V040 corr = 1:0370 2 (+2 80) + (00 10)
: : = +2:804
V05 corr = 1:0370 2 (02 60) + (00 10)
: : = 02 796
:

2.16) Check system gain:

The guide vane position schedule (GVPSTN_SCH) is generated within the PLC.
The PLC compares the schedule with the normalized feedback voltage (Vcorr) and
calculates an error signal. This error is amplified with the Kval GVDRIVGAIN
(GUIDE VANE CONTROL GAIN). The gain is set to a value of 2.0 to 2.5 and
normally does not require any correction. When the scheduled IGV angle and the
normalized position feedback match, the error is zero.
The amplified error signal is sent to the hydraulic guide vane positioner L339.
2.17) Compensate hydraulic positioner bias:
The hydraulic guide vane positioner (L339) is slightly biased in the positive direc-
tion. Upon loss of power, this "bias" acts like a positive control signal and closes
the IGV.
To keep the IGV actuators in a steady state position, L339 requires a negative
control signal. To avoid a permanent error when generating this signal (step 2.16),
"Kval" GVDRIVOFST (GUIDE VANE DRIVE OFFSET) is added to the error
signal. GVDRIVOFST is nominally set to -0.75, but should be optimized for the
actual bias in each "guide vane positioner" L339:
– Set GVPSTN_SCH to -2.80 by entering this value into "Kval" GVOPENLMT
(test crank switch is still "on"). The IGV open to about -5. IGV are not allowed
to touch the mechanical maximum stop.
– Vary "Kval" GVDRIVOFST (GUIDE VANE DRIVE OFFSET) until the
corrected guide vane position signal (GVPOSITION in the control logic,
not the actual IGV position) is identical to above value (-2.80). The error
calculated by the PLC is now zero and "Kval" GVDRIVOFST compensates
for the bias in L339.

NOTE
Due to the proportional only control, slight actual IGV changes will happen
during this adjustment.

2.18) Fine tune the actual position at an IGV angle near the maximum stop setting:
Minimal changes only should be required at this stage:

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NUMBER: 8.6/106
 – Pick an IGV angle 1 below the mechanical maximum stop setting of your
particular machine (IGVMax - 1). Angle may be positive or negative.
– Calculate the guide vane position schedule (GVPSTN_SCH) for this IGV angle
(SMax - 1):

Smax 01 = 03 6 0
: 0:16 2 (I GVmax01 )

– Enter SMax - 1 as "Kval" GVOPENLMT (GUIDE VANE OPEN LIMIT)

– Observe actual IGV angle. Trim Kval GVPSIPOFST (GUIDE VANE
POSITION OFFSET CORR) for a complete match. IGV are not allowed to
touch the mechanical maximum stop.
2.19) Readjust the guide vane failure threshold. Kval GVCLTSTLVL (GUIDE
VANE CLOSE TEST LEVEL) checks this limit during engine cranking. Due to
the optimized guide vane feed back signal, this value should now be set to +3.3.
2.20) Stop engine cranking or servo oil pump. Return crank switch to "off"
position.
Reactivate fuel gas and start system.
2.21) Return "Kval" GVOPENLMT to -4.4 and correct list 2.2).
2.22) Operate engine. Confirm normal operating temperature in lube oil header
and tank. Vary engine speed and verify correct IGV operation. Be sure to read
each IGV angle during engine acceleration and deceleration. Readings should not
vary more than ±1.0.
NGP corr IGV angle Tolerance
92.0% 0
90.0% -7.5
86.0% -22.5
82.0% -37.5
80.0% -45.0 ±1.0
82.0% -37.5
86.0% -22.5
90.0% -7.5
92.0% 0

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NUMBER: 8.6/106
 NOTE
– Due to a negative maximum IGV setting, some engines will not reach
zero degree IGV.
– IGV angles above 92% NGP corr follow a different schedule and must not
be used in this comparison.

2.23) Repeat adjustment procedure if IGV tolerances are not within ±1.0.
Stop engine when calibration and adjustment are satisfactory. Re-install IGV cov-
ers.
2.24) Reset Kval GVAG_OFFST to its original value as recorded in step 1.1).
2.25) Update drawings with new Kvals and back up PLC ladder files.
2.26) Operate equipment and wait for lube oil temperatures to stabilize.
Observe IGV movement. Use Figure 1 to confirm correct IGV operation.

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NUMBER: 8.6/106