Woodward VariStroke-I, Product Manual

Page 1: ...Product Manual 26727 Revision R 1 2020 Original Instructions VariStroke I VS I Electro hydraulic Actuator Installation and Operation Manual Released...

Page 2: ...to the equipment Any such unauthorized modifications i constitute misuse and or negligence within the meaning of the product warranty thereby excluding warranty coverage for any resulting damage and i...

Page 3: ...ng the VariStroke I Service Tool 58 Connecting to the VariStroke I 62 CHAPTER 5 CALIBRATION AND MONITORING 63 Introduction 63 System Information 63 System Information Page 65 Configuration and Calibra...

Page 4: ...Bore Remote Servo Cylinder V45RD 15XX 115 Appendix I V45 Servo 8 inch 200mm Bore Remote Servo Cylinder V45RD 20XX 118 Appendix J V45 Servo 10 inch 250mm Bore Remote Servo Cylinder V45RD 25XX 121 Appe...

Page 5: ...Incorrect Lifting Method 41 Figure 3 6 Suggested Configuration 43 Figure 3 7 Electrical Wiring Diagram 45 Figure 3 8 Power Supply Input Connections 46 Figure 3 9 Correct Wiring to Power Supply Input 4...

Page 6: ...te Installation Dimensions 119 Figure I 1c V45RD 20XX Remote Installation Dimensions 120 Figure J 1a VS I Remote Maximum Allowable Distance Between Actuator and Servo 121 Figure J 1b V45RD 25XX Remote...

Page 7: ...pecifications 23 Table 2 7 Special Ambient Temperature Specifications Allowances 25 Table 2 8 VS I Installation Drawings 31 Table 3 1 VS I Installation Bolts and Bolting Torques Recommendation 37 Tabl...

Page 8: ...overspeed shutdown device to protect against runaway or damage to the prime mover with possible personal injury loss of life or property damage The overspeed shutdown device must be totally independe...

Page 9: ...ing and Protection of Electronic Controls Printed Circuit Boards and Modules Follow these precautions when working with or near the control 1 Avoid the build up of static electricity on your body by n...

Page 10: ...for CE Marking These listings are limited only to those units bearing the CE Marking Review the Compliance Code table for more information EMC Directive Declared to Directive 2014 30 EU of the Europe...

Page 11: ...ents stated in Art 2 4 c and as such the product is excluded from the scope of RoHS2 EAC Customs Union These listings are limited only to those units with labels marking and manuals in Russian languag...

Page 12: ...in width of joint L mm Comment Spool to Spacer 0 079 13 46 Sleeve to Spacer 0 079 12 85 Sleeve to Sleeve 0 048 14 76 Sleeve to Housing 0 076 15 85 Sensor to Plate 0 08 36 25 Plate to Housing 0 10 22 9...

Page 13: ...lever les couvercles ni raccorder d brancher les prises lectriques sans vous en assurez auparavant que le syst me a bien t mis hors tension ou que vous situez bien dans une zone non explosive La subst...

Page 14: ...nal servo valve return spring forces the actuator to a failsafe position to safely close turbine control valves upon any internal unit failure electrical input power failure position sensor failure pr...

Page 15: ...As a way of allowing turbine control optimization the VariStroke I includes an 11 point linearization table to allow turbine OEMs or users to compensate for poor valve linearization by digitally linea...

Page 16: ...ariStroke I is made up of the following major components Figure 1 1 1 Hydraulic Power Cylinder 2 Rotary Servo Valve 3 Feedback Sensors MLDT Magnetostrictive Linear Displacement Transducer for power cy...

Page 17: ...iStroke I Remote Servo Kit Figure 1 2 contains the same primary components as integrated version this kit allows the Hydraulic Power Cylinder to be mounted separately from the servo in applications wh...

Page 18: ...the other control port The combined action of the servo position controller and cylinder position controller modulate the power cylinder position as necessary to match the input demand Additionally th...

Page 19: ...rientation of the sensing magnet on the shaft The H bridge drive is regulated by the microprocessor to precisely control the servo valve position and maintain the cylinder stroke position demand Elect...

Page 20: ...mote Servo Only Construction The Remote Servo Figure 1 5 has the following major components 1 Rotary Servo Valve 2 PCB This information is available in the VS I Integrated and Remote Construction sect...

Page 21: ...VariStroke Performance Equation be satisfied see Chapter 2 Performance Index In order to control cylinder position the Cylinder must be equipped with a position feedback sensor The position sensor mus...

Page 22: ...ydraulic Actuator Woodward 20 Figure 1 6 Nomenclature and Ordering Number Encoder Note Chemically resistant versions are denoted CR in the Specials string of the VariStroke model number Please contact...

Page 23: ...in Spring VS Bore in VS Stroke in S T U V 4 4 84 170 351 14 28 63 5 6 3 162 353 780 36 78 7 173 3 4 162 353 780 27 59 130 8 3 393 793 1578 2996 87 3 176 3 350 7 700 4 393 793 1578 3035 75 5 132 3 263...

Page 24: ...ment damage is possible if the hydraulic connections are attached incorrectly backwards Reversed hydraulic connects will cause the actuator to operate backwards making the fail safe position opposite...

Page 25: ...utput Signal Analog 4 20 mA Input Voltage 15 Vdc power provided by VariStroke Linearity 0 04 Full Stroke Current Drain 100 mA Sensor Length 2 times the Cylinder Stroke Length Update Rate 1 ms Sensor C...

Page 26: ...VBD 438 20 UNF Pipe Size Between Remote Servo and Cylinder Diameter 25 4 mm 1 inch minimum Length 3 m 120 inch maximum Supply Fluid Flow Refer to following figures for Maximum Transient Flow Rate and...

Page 27: ...h multiple features that allow hydraulic fluid to constantly flow through the servo valve and power cylinder during normal operation This allows the hydraulic fluid to act as a coolant on many of the...

Page 28: ...se is a primary feature of the VariStroke there are limitations when paring a large servo valve with a relatively small cylinder volume Before purchasing or installing a VS I actuator the user should...

Page 29: ...riStroke I VS I Electro hydraulic Actuator Woodward 27 Figure 2 3 Performance Chart for 4 5 and 6 Bore Actuators Diagrams Functional Block Diagram Figure 2 4 Basic Device Block Diagram without Trip Fu...

Page 30: ...ke I VS I Electro hydraulic Actuator Woodward 28 VS I Integrated Hydraulic Schematic Figure 2 5 VS I Integrated Hydraulic Schematic VS I Remote Servo Hydraulic Schematic Figure 2 6 VS I Remote Hydraul...

Page 31: ...VariStroke I VS I Electro hydraulic Actuator Woodward 29 VS I Servo Only Hydraulic Schematic Figure 2 7 VS I Remote Servo Hydraulic Schematic Figure 2 8 VS I Spring Assist Integrated Hydraulic Schema...

Page 32: ...Manual 26727 VariStroke I VS I Electro hydraulic Actuator Woodward 30 Figure 2 9 VS I Spring Assist Remote Hydraulic Schematic Released...

Page 33: ...F V45RD 12XX V45 Servo 5 inch 127mm Bore Remote Servo Cylinder G V45RD 15XX V45 Servo 6 inch 150mm Bore Remote Servo Cylinder H V45RD 20XX V45 Servo 8 inch 200mm Bore Remote Servo Cylinder I V45RD 25...

Page 34: ...nder any orientation is acceptable b Servo valve any orientation except upside down Recommend vertical orientation 3 Service Manual Replacement Parts a Servo Valve Consult Woodward for part number b H...

Page 35: ...ve atmosphere External fire protection is not provided in the scope of this product It is the responsibility of the user to satisfy any applicable requirements for their system Take care not to damage...

Page 36: ...it board If the VS I actuator is to be installed in close proximity to uninsulated unshielded steam valves or piping radiation heat shields should be installed between the actuator and these hot surfa...

Page 37: ...Manual 26727 VariStroke I VS I Electro hydraulic Actuator Woodward 35 Figure 3 1b VS I Integrated Product Installation Interface Bolting Pattern and Installation Features Released...

Page 38: ...27 VariStroke I VS I Electro hydraulic Actuator Woodward 36 Installation Dimensions for Remote Servo Kit Figure 3 2a VS I Remote Product Installation Interface Bolting Pattern and Installation Feature...

Page 39: ...t Grade Bolting Torque lbf ft Nm Thread Tol Class Male Female 4 100 M14x2 1 20 30 5 10 9 50 55 68 75 6H 5 127 M16x2 1 60 40 6 10 9 110 120 149 163 6H 6 152 M16x2 1 60 40 6 10 9 110 120 149 163 6H 8 20...

Page 40: ...c Hydraulic Rod position for different cylinders versions Fail Extend Spring Assist Cylinders with no hydraulics have cylinder rod in fully extended position For all fail retract spring assist cylinde...

Page 41: ...3 VS I Remote Servo Product Installation Interface Bolting Pattern Minimum Bolt Grade Bolting Torque and Thread Engagement Recommendation is valid for low carbon steel mounting surface to which produ...

Page 42: ...h lifting brackets for vertical lifting When transporting use both brackets as shown below Remote Servo and Remote Cylinder have their own separate lifting features Transport both Integrated and Remot...

Page 43: ...aintain the minimum required gap between servo valve and the actuator installation surface For reference see outline drawing Figure 3 1 Any mounting deviation from the one recommended by Woodward migh...

Page 44: ...I Remote Servo Kit and Servo Only options there is an additional hydraulic connection between servo and cylinder 1 000 SAE J518 Code 61 Flange for Hydraulic Control Ports Note SAE J518 JIS B 8363 ISO...

Page 45: ...of nominal value during slew step The hydraulic supply capacity should be large enough to supply the required slew rate of the attached servo system See Hydraulic Supply Specifications Significant red...

Page 46: ...oodward 44 For step demands and or trip movements actuator may generate pressure spikes in supply line due to water hammer effect Hydraulic accumulator in supply line installed close to the VariStroke...

Page 47: ...ng diagram Detailed wiring requirements for these connections will follow in the remainder of the Electrical Connections section The RS 232 connection is covered in Chapter 4 Installing and Running th...

Page 48: ...e requirement The VS I is not equipped with an input power disconnect A means of disconnecting input power to the VS I must be provided for safe installation and servicing The VS I is not equipped wit...

Page 49: ...se Wire Gauge Requirements 1 5 2 5 mm 12 16 AWG Maximum Wiring Distance 30 m Unit Grounding Ground the unit housing using the designated PE ground connection point and EMC ground connection point see...

Page 50: ...hen bundling the field wiring inside the unit separate the unshielded power and discrete inputs outputs from the shielded analog signals Shield Installation Notes Wires exposed beyond the shield shoul...

Page 51: ...Input Range 0 to 25 mA the recommended maximum range is 2 to 22 mA Maximum Temperature Drift 200 ppm C Input Impedance 200 10 Common Mode Voltage Range 50 V dc Common Mode Rejection Ratio 70 db 50 Hz...

Page 52: ...C Input Impedance 235 25 Loop power 15 V 0 5 V over temperature range Max output current 200 mA total 100 mA per sensor Common Mode Voltage Range 50 V dc Common Mode Rejection Ratio 70 dB 50 Hz 60 Hz...

Page 53: ...of Incorrect Cylinder Position Sensor Connection When Using External Power Supply When using external power supply do NOT connect it to VS I driver power outputs on the Position Feedback terminals Th...

Page 54: ...ervice tool chapter for configuration information The design of this output is for monitoring and diagnostic purposes only and not intended for any type of closed loop feedback Figure 3 19 Analog Outp...

Page 55: ...Figure 3 20 Discrete Inputs Connections Contact Types The inputs will accept either a dry contact from each terminal to ground or an open drain collector switch to ground Approximately 3 mA is source...

Page 56: ...mation Wire the outputs to switch load from positive supply or switch load to ground Woodward recommends that the output be used as a high side driver as shown in the diagram below This configuration...

Page 57: ...the wires should be kept in a twisted configuration for noise immunity CAN Communication CAN communication is not yet available in current VS I models The VS I has 2 CAN ports Figure 3 22 CAN Ports C...

Page 58: ...meet the same hazardous locations criteria as the VS I Follow all installation recommendations and special conditions for safe use that are supplied with the cable gland The cable insulation must hav...

Page 59: ...View diagnostic flags An unsafe condition could occur with improper use of these software tools Only trained personnel should have access to these tools The PC Service Tool or Programming and Configu...

Page 60: ...on Clean the surface with rubbing alcohol if necessary Inspect the cover joint surfaces to ensure that they are not damaged or contaminated Installing the VariStroke I Service Tool Use the following i...

Page 61: ...te xxx is a placeholder for the revision of the install package i e 9927 2177_NEW exe or 9927 2177_A exe are examples of Rev NEW and Rev A versions 2 The Tool launches and the Welcome screen is displa...

Page 62: ...Installation Screen 5 The Installation of the Service tool will proceed Figure 4 5 Service Tool Installation Progress Screen 6 When the installation is finished the Installation Complete screen will a...

Page 63: ...u connect the serial cable between the computer and the VS I the service tool will not detect the new serial connection To detect the connection you will have to exit and re launch the service tool 7...

Page 64: ...able is connected Select your available network and then set Baud Rate to AutoDetection Press the Connect button 4 The Service Tool will connect to the VS I within a few seconds When it does the Conne...

Page 65: ...damage to the prime mover with possible personal injury loss of life or property damage The overspeed shutdown system must be totally independent of the prime mover control system An overtemperature...

Page 66: ...because the analog inputs are not in the 4 20 mA range or the Run Enable discrete input is selected and not on or the Shutdown button has been pressed After checking that the analog demands and the Ru...

Page 67: ...the VS I software Servo P N S N Revision These fields display the Servo Valve Part Number S_P N Serial Number S_S N and Revision Number This information is entered automatically by the VS I software...

Page 68: ...down Direction Fail Retracted Fail Extended This indicates the fail safe direction of the actuator Any shut down or loss of input power will result in the actuator moving in the fail safe direction Sy...

Page 69: ...20 mA range For a list of standard Woodward position sensor lengths used in Integrated and Remote Servo Kits refer to the table shown in Chapter 7 Repair and Troubleshooting Reverse Acting The user b...

Page 70: ...te limit when positioned within the lower 0 to 25 of the user calibrated stroke This feature provides a behavior similar to that of a conventional hydraulic cushion You may use this function to limit...

Page 71: ...r attachments IF the linkage and or attachments CANNOT WITHSTAND THE FULL STALL FORCE of the actuator DO NOT USE FIND MINIMUM AND MAXIMUM STOPS Instead Find Minimum Stop must be used Find Minimum Stop...

Page 72: ...ing the Cancel button will cause the Find Minimum Stop process to stop and the service tool to return to the Calibration page Find Minimum AND Maximum Stops ALL SHUTDOWNS must be cleared in order to p...

Page 73: ...this as the maximum 20 mA demand position These limits of travel are automatically scaled to 4 mA minimum to 20 mA maximum demand levels Press the Find Minimum AND Maximum Stops button A confirmation...

Page 74: ...settings are presented in millimeters for user convenience If a specific stroke length is required the user shall adjust these parameters while verifying the actual actuator minimum and maximum positi...

Page 75: ...recommended The VS I can be put into manual mode by pressing the Manual Operation button The VS I can be returned to normal operation by pressing the Exit button by enabling Run Enable or by supplying...

Page 76: ...he minimum input demand current 4 mA default that is used to position the actuator to 0 Note only after VS I shut down may values be saved Maximum Analog Demand In Indicates the maximum input demand c...

Page 77: ...signal is supplied the actuator will operate while outputting and alarm for the other signal Feedbacks Position Feedback 1 and 2 Shows the current position of the cylinder in percent Feedback This ind...

Page 78: ...Tool or by stepping the Analog Demand Inputs from 0 to 4 mA Output Configuration Output Configuration Page Figure 6 2 Output Configuration Screen Alarm Shutdown Discrete Outputs Alarm Shutdown Indicat...

Page 79: ...will only be displayed when the Mode is set to Cylinder Position Low Indication Cylinder Position High Indication Sets the discrete output to energize whenever the cylinder is above the configured Ene...

Page 80: ...d if the actuator is connected to a pilot valve to overcome sticky pilot valve action The higher the setting the higher the output shaft is oscillating amplitude It is recommended that the Dither func...

Page 81: ...e Linearization Curve is enabled Scaled Analog Position These are the cylinder output positions steam valve position that will result when the demand is equal to the values put in to the Analog Positi...

Page 82: ...S I Electro hydraulic Actuator Woodward 80 Figure 6 5 Alarms and Shutdowns Screen Diagnostic Values Supply Voltage Indicates the supply voltage value Internal Actuator Drive Current Indicates the actu...

Page 83: ...active Alarm is toggled to a Shutdown the actuator will immediately shut down It is recommended that the alarm be disabled before configuring it and then re enabled when configuration is completed Ena...

Page 84: ...s for the user s future reference These settings can also be loaded in to another VS I should the unit ever be replaced To save the VS I settings click on Settings in the ribbon at the top left of the...

Page 85: ...odward It is recommended that all repairs and servicing of the VS I be performed by Woodward or its authorized service facilities Use of a cable gland or stopping plug that does not meet the hazardous...

Page 86: ...Manual 26727 VariStroke I VS I Electro hydraulic Actuator Woodward 84 Figure 7 1 Shaft Seals Replacement Kits and Installation Released...

Page 87: ...hut down of the turbine or other type of prime mover to protect against runaway or overspeed with possible personal injury loss of life or property damage EXPLOSION HAZARD Do not remove covers or conn...

Page 88: ...Tool view the Alarms Shutdowns page to determine the fault Use the remainder of this chapter to determine the cause and solution to the fault Position Sensor Loop Power Output Overloaded Remote Servo...