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Woodward VariStroke-DX, Installation And Operation Manual

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Woodward VariStroke-DX Installation And Operation Manual Download Page 32

Manual 35132 

VariStroke-DX Duplex Hydraulic Servo Skid 

 

 

 

Woodward 

30 

 

2.  Open VariStroke Cover (using Wrench: Type: Open End; Size: 2 1/4 in, CCW direction )  
 
 
 
 
 
 

 

 
3.  Connect Communication Cable to VariStroke communication port.  

 

 

 
To perform VS unit calibration please follow procedure steps according to Woodward manual 35148

  

(VS-GI Customer Service Tool User Manual). 
 
Once calibration is complete, several transfers should be completed between both VS-I’s with a common 
demand signal of 12 mA to ensure that the output of both VS-I’s responds correctly to a switching 
demand but also damps quickly and is stable after transfer. 
 
To aid with calibration, pressure gages are provided on the skid assembly (see Figure 3-9). These gages 
indicate which unit is in control. 
 

Released

Summary of Contents for VariStroke-DX

Page 1: ...Product Manual 35132 Revision 3 2020 Original Instructions VariStroke DX Duplex Hydraulic Servo Skid Installation and Operation Manual Released...

Page 2: ...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 ii...

Page 3: ...Wiring 29 VS DX Configuration and Calibration 29 CHAPTER 4 INITIAL OPERATION 32 VS DX performance 38 VSC DX Unit Trapped Air Releasing Procedure 39 VSC DX Unit Tuning 39 CHAPTER 5 REPAIR AND TROUBLES...

Page 4: ...out Junction Box Version Wiring Diagram 25 Figure 3 6 Cylinder Position Sensor Connection Scheme 26 Figure 3 7 PE Ground Connection Localization and Details Junction Box Version 28 Figure 3 8 PE Chass...

Page 5: ...dependent of the prime mover control system An overtemperature or overpressure shutdown device may also be needed for safety as appropriate Personal Protective Equipment The products described in this...

Page 6: ...or conductors on a printed circuit board with your hands or with conductive devices To prevent damage to electronic components caused by improper handling read and observe the precautions in Woodward...

Page 7: ...F Maximum hydraulic fluid temperature shall not exceed 70 C 158 F Connect external safety ground terminal to earth ground Compliance with the Machinery Directive 2006 42 EC noise measurement and mitig...

Page 8: ...t d cid ment non dangereuse La substitution de composants peut rendre ce mat riel inacceptable pour les emplacements de Classe I applications Division 2 ou Zone 2 Safety Symbols Direct Current Alterna...

Page 9: ...ontrol during VS DX startup CMRR Common Mode Rejection Ratio VHPC VariStroke Hydraulic Power Cylinder Table 1 2 Woodward Reference Literature Manual 25071 Oils for Hydraulic Controls Manual 25075 Comm...

Page 10: ...e system uptime is essential The utilized VariStroke GI servos superb accuracy and resolution make it ideal for steam turbine valve control As a result of this servo s integrated redundancy and when u...

Page 11: ...kid s output drain line In this state if the In Control servo or its input demand signal fail the servo s output is stepped to a failsafe zero pressure level the Not In Control servo is switched to an...

Page 12: ...igure 1 5 Figure 1 2 VS DX Main Components Junction Box Version The complete assembly is designed for use in a hazardous environment see the Regulatory Compliance specifications for more details Integ...

Page 13: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 11 Figure 1 3 VariStroke DX Junction Box Version front view Figure 1 4 VariStroke DX Junction Box Version Top View Released...

Page 14: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 12 Figure 1 5 VariStroke DX Junction Box Version Bottom View Figure 1 6 VariStroke DX Junction Box Version Back View Released...

Page 15: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 13 Figure 1 7 VariStroke DX Junction Box Version Side View Released...

Page 16: ...nual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 14 Figure 1 8 VariStroke DX Without Junction Box Version Front View Figure 1 9 VariStroke DX Without Junction Box Version Rear View Releas...

Page 17: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 15 Figure 1 10 VariStroke DX Without Junction Box Version Bottom View Released...

Page 18: ...minals suitable for 0 14 to 6 mm 26 to 10 AWG stranded wire power and ground terminals 0 2 to 4 mm 24 to 12 AWG stranded wire communication signal terminals Junction box Cable Entries 4 x 3 4 NPT COND...

Page 19: ...ble for NO or NC 0 5 A at 24 V dc max 32 V dc 0 5 A inductive at 28 V dc 0 2 Henry Discrete Input Signal Contact current 3 8 mA typ input closed Max input voltage 32 V dc High signal threshold 7 V Low...

Page 20: ...Pressure 3 45 bar g 50 psig It is highly recommended to maintain drain pressure level as low as possible to avoid operating issues with single acting type cylinders It is highly recommended that inlet...

Page 21: ...nvironments hearing protection should be worn when working on or around the VS DX Hot Surfaces The surface of this product can become hot enough or cold enough to be a hazard Use protective gear for p...

Page 22: ...mounting VS DX near heat sources and provide adequate ventilation Mount VS DX using four 4 0 625 11 UNF size screws UNF Class 8 8 minimum Bolts thread engagement min 0 7 inch maximum 1 inch bolts not...

Page 23: ...stalling electrical electronic equipment and where applicable for installing explosion proof devices in hazardous environments Due to the hazardous location listings associated with this product prope...

Page 24: ...uplex Hydraulic Servo Skid Woodward 22 Figure 3 2 VariStroke DX Junction Box Version Main Terminal Box Wiring Points Access It is important that during operation the setpoint signals to both servos ar...

Page 25: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 23 Figure 3 3 VariStroke DX Junction Box Version Main Terminal Block Connections Chart Released...

Page 26: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 24 Figure 3 4 VariStroke DX Junction Box Version Wiring Diagram Released...

Page 27: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 25 Figure 3 5 VariStroke DX VariStroke DX Without Junction Box Version Wiring Diagram Released...

Page 28: ...out accuracy A hazardous accessible voltage on the external cylinder chassis which could result in electric shock The severity of this shock risk is dependent upon each installation configurations of...

Page 29: ...t 3 is dedicated to a redundant pair configuration The two VS GI s communicate which unit is in control via a pulse train on these discrete lines Redundant Link Input must be wired to Redundant Link O...

Page 30: ...box Figure 3 7 PE Ground Connection Localization and Details Junction Box Version In VS DX with Junction Box version for the PE connection use the required type wire typically green yellow 3 to 6 mm...

Page 31: ...bove the maximum ambient or fluid temperature whichever is greater 1 Strip the cable insulation not the wire insulation to expose 12 cm of the conductors Strip the wire insulation 5 mm from each condu...

Page 32: ...ording to Woodward manual 35148 VS GI Customer Service Tool User Manual Once calibration is complete several transfers should be completed between both VS I s with a common demand signal of 12 mA to e...

Page 33: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 31 Figure 3 9 VS DX Skid Pressure Gauges Location Released...

Page 34: ...Incorrect operation or improper tuning could cause erratic operation when the system is operated automatically by the turbine control system Proper tuning is essential before transferring to automatic...

Page 35: ...cause personal injury and or property damage The VS DX can be controlled remotely make sure area is clear before connecting tool Entering manual modes and or changing modes may change the state of dev...

Page 36: ...nd control isolation valve to both VS GI units and drain isolation valves not provided if necessary Make sure that VS DX skid and VS GI s drain port are opened before supply valves opening SERVO A ISO...

Page 37: ...Maximum Demand In signal 4 20 mA input please refer Woodward Manual 35148 for instructions 10 Use the Customer Service Tool to adjust all Input signals required for VS GI operation 11 Use the Customer...

Page 38: ...isolation valve on the VS GI Unit B 27 Slowly open the Supply isolation valve to VS GI Unit B 28 Use the Customer Service Tool to initiate automatic VS GI unit A trapped air flashing please refer Woo...

Page 39: ...placing a failed VS GI Servo always use the following order to ensure there are no interactions with the operating servo 1 Power down the failed unit 2 Close and lock out the control isolation valve 3...

Page 40: ...t construction Diagrams below show typical transfer performance Figure 4 6 VS DX Unit to Unit Control User Demanded Switchover Action Typical Performance Demanded position 61 0 Position MAX 61 5 Posit...

Page 41: ...8 VS GI Customer Service Tool User Manual to flush VS GI servo and release trapped air from the unit mandatory after VS GI servo online replacement When replacing a failed VS GI Servo to ensure stable...

Page 42: ...the unit Table 5 1 List of available Replacement Kits P N to order Description 1 8935 1340 KIT VS 1 REPLACEMENT WITHOUT JUNCTION BOX VERSION FAIL EXTEND FOR VS DX SKID 2 8935 1341 KIT VS 1 REPLACEMENT...

Page 43: ...system problems In general most problems are a result of incorrect wiring or installation practices Make sure that the system wiring input output connections controls and contacts are correct and in g...

Page 44: ...r trapped in VS DX control path Perform trapped air releasing procedure Slow dynamics Dynamic adjustments not optimal Adjust primary gain parameter Cold oil viscosity too high Wait until normal temper...

Page 45: ...cylinder position hysteresis Abnormal high friction Adjust control dither in VS GI Clean or change power cylinder power cylinder linkage Excessive input control noise Reduce or eliminate dither at tur...

Page 46: ...th an equipment system should also be handled through the OEM or Packager Please review your equipment system documentation for details Woodward Business Partner Support Woodward works with and suppor...

Page 47: ...All repair work carries the standard Woodward service warranty Woodward Product and Service Warranty 5 01 1205 on replaced parts and labor Flat Rate Remanufacture Flat Rate Remanufacture is very simi...

Page 48: ...worldwide locations or from one of our Full Service Distributors The field engineers are experienced both on Woodward products as well as on much of the non Woodward equipment with which our products...

Page 49: ...r Type of Fuel gas steam etc Power Output Rating Application power generation marine etc Control Governor Information Control Governor 1 Woodward Part Number Rev Letter Control Description or Governor...

Page 50: ...to eight years depending on the site and application During major outages Woodward recommends the VS GI be sent back to Woodward or a Woodward Authorized Service Facility AISF for inspection component...

Page 51: ...uplex Hydraulic Servo Skid Woodward 49 Chapter 8 Long Term Storage Requirements Units that will not be put into service within twelve months should be packaged for long term storage as described in Wo...

Page 52: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 50 Revision History New Manual Released...

Page 53: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 51 Declarations PENDING Released...

Page 54: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 52 Released...

Page 55: ...Manual 35132 VariStroke DX Duplex Hydraulic Servo Skid Woodward 53 Released...

Page 56: ...2 1519 USA 1041 Woodward Way Fort Collins CO 80524 USA Phone 1 970 482 5811 Email and Website www woodward com Woodward has company owned plants subsidiaries and branches as well as authorized distrib...

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