Woodward 3103 User manual

Product Manual 26734
(Revision H, 7/2022)
Original Instructions
3103 Gas Valve with
EM35MR Electric Powered Actuator
Installation and Operation Manual
Released

General
Precautions
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
This publication may have been revised or updated since this copy was produced.
The latest version of most publications is available on the Woodward website.
http://www.woodward.com
If your publication is not there, please contact your customer service
representative to
g
et the latest cop
y
.
Proper Use
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage 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
dama
g
e, and
(
ii
)
invalidate product certifications or listin
g
s.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. The latest version of most publications is available on the
Woodward website.
www.woodward.com/publications
Always compare with the original for technical specifications and for proper and
safe installation and operation procedures.
If your publication is not on the Woodward website, please contact your customer
service representative to
g
et the latest cop
y
.
Revisions— A bold, black line alongside the text identifies changes in this publication since the
last revision.
Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 26734
Copyright © Woodward, Inc. 2014 - 2022
All Rights Reserved
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Manual 26734 3103 Gas Valve with EM35MR Actuator
Woodward 1
Contents
WARNINGS AND NOTICES ............................................................................................................... 3
ELECTROSTATIC DISCHARGE AWARENESS...................................................................................... 4
REGULATORY COMPLIANCE ............................................................................................................ 5
CHAPTER 1. GENERAL INFORMATION .............................................................................................. 8
Introduction ................................................................................................................................................... 8
EM35MR Actuator......................................................................................................................................... 9
Resolver ........................................................................................................................................................ 9
Applications................................................................................................................................................... 9
CHAPTER 2. INSTALLATION ........................................................................................................... 10
Unpacking ................................................................................................................................................... 10
Power Requirements................................................................................................................................... 10
EM Actuator/3103 Gas Valve Installation ................................................................................................... 17
Piping Installation ........................................................................................................................................ 17
Electrical Connections................................................................................................................................. 18
CHAPTER 3. DESCRIPTION OF OPERATION .................................................................................... 21
EM35MR Actuator....................................................................................................................................... 21
3103 Gas Valve........................................................................................................................................... 21
Water Ingress Protection............................................................................................................................. 22
CHAPTER 4. ACTUATOR/VALVE CALIBRATION ............................................................................... 23
EM35MR Actuator/3103 Gas Valve with Driver.......................................................................................... 23
CHAPTER 5. TROUBLESHOOTING AND FIELD REPLACEMENT.......................................................... 25
General........................................................................................................................................................ 25
Troubleshooting .......................................................................................................................................... 25
Procedure for EM35 Actuator Field Replacement ...................................................................................... 26
CHAPTER 6VALVE SIZING-NON-DLE APPLICATIONS..................................................................... 29
Determination of Effective Area .................................................................................................................. 29
Valve Sizing and the Effective Area Tables ................................................................................................ 30
Determining the Demand Required to Achieve Specific Flows .................................................................. 31
CHAPTER 7. MAINTENANCE .......................................................................................................... 35
CHAPTER 8. PRODUCT SUPPORT AND SERVICE OPTIONS .............................................................. 36
Product Support Options............................................................................................................................. 36
Product Service Options ............................................................................................................................. 36
Returning Equipment for Repair ................................................................................................................. 37
Replacement Parts...................................................................................................................................... 38
Engineering Services .................................................................................................................................. 38
Contacting Woodward’s Support Organization ........................................................................................... 38
Technical Assistance .................................................................................................................................. 39
3103/EM35MR SPECIFICATIONS .................................................................................................. 40
REVISION HISTORY ....................................................................................................................... 41
DECLARATIONS ............................................................................................................................ 42
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Illustrations and Tables
Figure 2-1a. EM35MR Actuator/3103 Gas Valve/Resolver Outline (NPT electrical conduit entries) ......... 11
Figure 2-1b. EM35MR Actuator/3103 Gas Valve/Resolver Outline............................................................ 12
Figure 2-2a. EM35MR Actuator/3103 Gas Valve/Resolver Outline............................................................ 13
Figure 2-2b. EM35MR Actuator/3103 Gas Valve/Resolver Outline............................................................ 14
Figure 2-3a. EM35MR Actuator/3103 Gas Valve 900 psig PED/Resolver Outline..................................... 15
Figure 2-3b. EM35MR Actuator/3103 Gas Valve 900 psig PED/Resolver Outline..................................... 16
Figure 2-4. WAGO 264 Series Terminal Block ........................................................................................... 20
Figure 3-1. Conduit Plug (M25 Shown) & Warning Label........................................................................... 22
Figure 5-1. Where to Locate the Coupling Assembly ................................................................................. 26
Figure 5-2. Identifying the Coupling Clamp Screw ..................................................................................... 27
Figure 5-3. Removing Socket Head Cap Screws ....................................................................................... 27
Table 2-1. Class 600 Bolt Length and Diameter......................................................................................... 18
Table 6-1. 3103 1.0 in² port, Effective Area ................................................................................................ 32
Table 6-2. 3103 1.5 in² port, Effective Area ................................................................................................ 33
Table 6-3. 3103 2.0 in² port, Effective Area ................................................................................................ 34
The following are trademarks of Woodward, Inc.:
MicroNet
NetCon
Woodward
The following are trademarks of their respective companies:
Teflon (DuPont Company)
Viton (DuPont Performance Elastomers)
WAGO (WAGO Corporation)
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Warnings and Notices
Important Definitions
This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all
safety messages that follow this symbol to avoid possible injury or death.
DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious
injury.
CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate
injury.
NOTICE - Indicates a hazard that could result in property damage only (including damage to the
control).
IMPORTANT - Designates an operating tip or maintenance suggestion.
Overspeed /
Overtemperature /
Overpressure
The engine, turbine, or other type of prime mover should be
equipped with an 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 independent of the
prime mover control system. An overtemperature or overpressure
shutdown device ma
y
also be needed for safet
y
, as appropriate.
Personal Protective
Equipment
The products described in this publication may present risks that
could lead to personal injury, loss of life, or property damage.
Always wear the appropriate personal protective equipment (PPE) for
the job at hand. Equipment that should be considered includes but is
not limited to:
Eye Protection
Hearing Protection
Hard Hat
Gloves
Safety Boots
Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
workin
g
fluid
(
s
)
and compl
y
with recommended safet
y
equipment.
Start-up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
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Electrostatic Discharge Awareness
Electrostatic
Precautions
Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
contact while handling the control).
Avoid all plastic, vinyl, and Styrofoam (except antistatic
versions) around printed circuit boards.
Do not touch the components 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 manual
82715 , Guide for Handling 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 not wearing clothing made of synthetic
materials. Wear cotton or cotton-blend materials as much as possible because these do not store
static electric charges as much as synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary.
If you must remove the PCB from the control cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the components with conductive
devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in
until you are ready to install it. Immediately after removing the old PCB from the control cabinet,
place it in the antistatic protective bag.
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking.
Pressure Equipment
Directive (Valve):
Directive 2014/68/EU on the harmonisation of the laws of the Member
States relating to the making available on the market of pressure
equipment.
PED Category II
PED Module H – Full Quality Assurance,
CE-0062-PED-H-WDI 001-20-USA, Bureau Veritas SAS (0062)
ATEX Directive
(Actuator& Resolver):
Directive 2014/34/EU on the harmonisation of the laws of the Member
States relating to equipment and protective systems intended for use in
potentially explosive atmospheres
Zone 1: II 2 G, Ex db IIB T3 Gb SIRA 13ATEX1188X
EM35/EM35MR Actuator and 3103 Valve assemblies incorporating
the minimum position switch are not suitable for use in an ATEX
environment.
Other European Compliance:
Compliance with the following European Directives or standards does not qualify this product for
application of the CE Marking:
ATEX (Valve): Exempt from the ATEX Directive 2014/34/EU as non-electrical equipment
bearing no potential ignition sources per EN ISO 80079-36:2016 for Zone
1 installation
EMC Directive: Not applicable to this product. Electromagnetic, EMC, passive devices are
excluded from the scope of the 2014/30/EU Directive.
Machinery Directive: Compliant as partly completed machinery with Directive 2006/42/EC of the
European Parliament and the Council of 17 May 2006 on machinery.
RoHS Directive: Restriction of Hazardous Substances 2011/65/EU:
Woodward Turbomachinery Systems products are intended exclusively for
sale and use only as a part of Large Scale Fixed Installations per the
meaning of Art.2.4(e) of directive 2011/65/EU. This fulfills the requirements
stated in Art.2.4(c) and as such the product is excluded from the scope of
RoHS2.
North American Compliance:
These listings are limited only to those units bearing the UL and/or CSA identification.
Suitability for use in North American Hazardous Locations is the result of compliance of the individual
components:
Actuator and Resolver: CSA Certified for Class I, Division 1, Groups C & D, Class I, Division 2,
Groups B, C, and D, T3 at 93 °C Ambient. For use in Canada and the
United States. Certificate 1006295
Minimum Position
Switch:
CSA Certified for Class I, Division 1, Groups C & D, Class II, Division 2,
Groups E, F, and G. LR57324. UL Listed for Class I, Division 1, Groups C
& D, Class II, Division 2, Groups E, F, and G. E14274
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Special Conditions for Safe Use
Wiring must be in accordance with North American Class I, Division 1 or 2 or European Zone 1 wiring
methods as applicable, and in accordance with the authority having jurisdiction.
Ambient Temperature: (–40 to +93) °C / (–40 to +200) °F
Fuel Temperature: (–40 to +149) °C / (–40 to +300) °F
Use supply wires suitable for a maximum ambient temperature of +93 °C.
For ATEX Zone 1 and Zone 2 Applications: A conduit seal must be installed within 50 mm (2 inches) of
the conduit entries when the EM35MR Actuator and EM Resolvers are used in a Zone 1 or a Zone 2
ATEX classified explosive atmosphere. These are Category 2, flameproof, and type 'd' products.
For Class I, Division 1 or Class I, Zone 1 North American Applications: A conduit seal must be installed
within 45 cm (18 inches) of the conduit entry when the
EM35MR Actuator or EM Resolvers are used in a Class I, Division 1 or Class I, Zone 1 hazardous
atmosphere.
The surface of the gas valve is dependent upon the temperature of the fuel. Refer to the burn hazard
warning statement below for safe handling. Fuel temperature effects on valve surface temperature must
be taken into consideration when this product is used in an explosive atmosphere.
It should be noted that the following flame paths have a maximum
constructional gap that is smaller than IEC 60079-1 requires.
Flame Path Max Gap, ic (mm) Comment
Actuator Cover to
Housing
Per drawing 9989‐4011, the max gap permitted on
this flat
j
oint is 0.099 mm / 0.0039 inch.
Actuator Adaptor
Plate to Housing
Per drawing 9989‐4011, the max gap permitted on
this flat
j
oint is 0.099 mm / 0.0039 inch.
Resolver Cover to
Housing
Per drawing 9989‐4013, the max gap permitted on
this flat
j
oint is 0.102 mm / 0.004 inch.
Resolver Shaft Per drawing 9989‐4013, the max gap permitted on
this c
y
lindrical
j
oint is 0.152 mm / 0.006 inch.
Actuator Shaft Per drawing 9989‐4011, the max gap permitted on
this c
y
lindrical
j
oint is 0.152 mm / 0.006 inch.
EXPLOSION HAZARD—Do not connect or disconnect while circuit
is live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 1 or 2 or Zone 1 or 2 applications.
RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher
tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non-dangereuse.
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I,
applications Division 1 ou 2 ou Zone 1 ou 2.
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
GENERAL CONDITIONS FOR SAFE USE—Turbine control system
alarms, faults, or shutdowns that are initiated by the valve or valve
driver should not be ignored. These alarms, faults, and shutdowns
are intended to alert equipment operators of a potentially unsafe
condition and to protect against personal injury, loss of life, or
property damage. Valve position error alarm and shutdown
thresholds should be set to values that prevent improper fuel
metering flow rates during turbine light-off. Equipment operators
should strictly follow turbine OEM start procedures, including
pur
g
in
g
of the
g
as turbine after failed start attempts.
The risk of electrostatic discharge for painted units is reduced by permanent installation, proper
connection of the equipotential ground lugs, and care when cleaning. Painted units must not be cleaned
or wiped off/against unless the area is known to be non-hazardous.
POTENTIAL ELECTROSTATIC CHARGING HAZARD INSTRUCTIONS:
The risk of electrostatic discharge for painted units is reduced by
permanent installation, proper connection of the equipotential
ground lugs, and care when cleaning. Painted units must not be
cleaned or wiped off/against unless the area is known to be non-
hazardous.
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Chapter 1.
General Information
Introduction
Use the EM35MR electric actuator to drive a 3103-gas valve, closed loop to position demand. A resolver
connected to the valve-metering sleeve provides position feedback. Closed loop position control is
accomplished through an EM 24 V Digital Driver. Having the feedback on the valve allows repair or
changing of the motor assembly in the field without the loss of valve calibration.
3103 Gas Valve
The 3103 Gas Valve is a stainless-steel valve capable of metering gas flow between 23 kg/h and 18 144
kg/h (50 lb/h and 40 000 lb/h). The valve is designed to bolt into a 50 mm (2 inch) line by means of 0.625-
11 UNC 2B tapped holes. The flange is class 600 per ANSI B16.5. The valve design is a rotary metering
sleeve and a shoe-type throttling valve. The valve shoe is spring- and pressure-loaded against the
metering port to minimize leakage and to self-clean the metering port. Metering port area is determined
by input shaft positioning from the actuator. The valve has an internal spring to return the valve to the
minimum fuel position in the event of a power loss to the actuator.
The 3103 valve has redundant seals on all dynamic sealing surfaces. Between these two seals is an
overboard vent which vents any gasses that may leak past the first seal to safe vent location. The use of
an inner-seal vent prevents the second dynamic seal from seeing any differential pressure and thus offers
protection against the leakage of gasses from the valve into the surrounding ambient atmosphere.
The valve design incorporates an inlet guide tube to condition the inlet flow and to direct any gas
contaminants through the metering port, minimizing any accumulation in the valve housing. The metering
sleeve support bearings are positively sealed from the gas. Internal valve parts are made of through-
hardened stainless steel.
The valve has mechanical stop screws installed in the valve flange.
Customer, do not adjust these stops. If these stops interfere with the
valve-operating region or the electrical stops, it will cause the EM 24
V
Di
g
ital Driver to trip out on overcurrent.
The customer installation should provide proper fuel filtration and
adequate heating to prevent fuel saturation, constituent precipitation,
and/or hydrate formation on the valve-wetted parts. Performance
de
g
radation or valve failure ma
y
result.
The customer should take into account gas constituents that may
cause adverse material compatibility issues.
The customer should prevent installation debris from remaining on,
around, or within the valve housing or actuator junction box.
Electrical shortin
g
or contamination of the product ma
y
result.
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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EM35MR Actuator
The EM35MR actuator is an all-electric actuator designed for use in industrial gas turbine control
applications. The EM35MR actuator consists of a high-performance brushless servomotor and a precision
planetary gearbox with two resolver-type shaft position sensors. All stator windings are completely
sealed. The use of a high efficiency gearbox facilitates high servo system bandwidth. The motor has its
own resolver providing motor rotor position feedback, and the other resolver(s) provides accurate output
shaft position feedback. The actuator also has a slip clutch to allow full speed impact into optional
external rigid mechanical stops.
The motor assembly is housed in a cast aluminum explosion proof housing. A thermal potting compound
is used to transfer waste heat generated by the motor, to the cast, explosion-proof housing and out to the
ambient environment. Wiring to the motor is accomplished through two .750-14 NPT conduit connections
or two M25 x 1.5 conduit connections into a wiring compartment integral to the housing. One conduit is for
the motor power wires, the other is for the motor resolver wires. The motor output shaft is directly coupled
to the valve input shaft with a stainless-steel torsional coupling.
Resolver
Position feedback is accomplished using a highly accurate brushless resolver(s). The resolver is directly
coupled to the valve-metering shaft through use of a stainless-steel bellows and is housed in an explosion
proof enclosure. The resolver receives its excitation from the EM driver. The EM driver uses a resolver-to-
digital converter to determine valve position using the output voltages from the resolver's two secondary
windings. Resolver accuracy is ±0.05°. Wiring to the resolver is accomplished through two .750-14 NPT
conduit connections or two M25 x 1.5 conduit connections.
Applications
The 3103/EM35MR is well suited for metering flow to a gas turbine that is in continuous operation. When
used in applications where the turbine is frequently in a standby mode, remove power from the valve, or
place it in a slow cycle relubrication mode. Either of these procedures will prevent accelerated wear on
the actuator. See Woodward application note 51424 for additional information and/or contact Woodward
for details on how to implement these procedures.
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Chapter 2.
Installation
Unpacking
Be careful when unpacking the EM 24 V Digital Driver and EM35MR actuator/3103 gas valve. Check the
devices for signs of damage such as bent or dented case and loose or broken parts. If damage is found,
notify the shipper immediately. The devices may be stored in their original shipping containers until they
are ready for installation. Protect the devices from weather and from extreme humidity or temperature
fluctuations during storage.
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 s
y
stem.
The 3103/EM35MR assembly weight is approximately 44 kg (96 lb). In
order to prevent injury, use a lifting strap or other means of lifting
assistance when handlin
g
this product.
Due to typical noise levels in turbine environments, wear hearing
protection when working on or around the 3103 Gas Valve.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
Power Requirements
The EM35MR actuator receives all of its power from the EM driver. The full actuator operating range of
the actuator is (18 to 32) V (dc). The maximum steady state driver input current is 15 A continuous with
peaks of 37 A for 50 ms.
EXPLOSION HAZARD—For Zone 1 / Division 1 products: Proper
torque is very important to ensure that the unit seals properly.
Actuator cover bolt torque is:
0.250-28 socket head cap screw = 9.2 Nm (81 lb-in)
M6 x 1 socket head cap screw = 8.0 Nm (71 lb-in)
Resolver cover bolt torque is 9.2 Nm
(
81 lb-in
)
.
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Figure 2-1a. EM35MR Actuator/3103 Gas Valve/Resolver Outline
(NPT electrical conduit entries)
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Figure 2-1b. EM35MR Actuator/3103 Gas Valve/Resolver Outline
(NPT electrical conduit entries)
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Manual 26734 3103 Gas Valve with EM35MR Actuator
Woodward 13
Figure 2-2a. EM35MR Actuator/3103 Gas Valve/Resolver Outline
(metric electrical conduit entries)
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Manual 26734 3103 Gas Valve with EM35MR Actuator
Woodward 14
Figure 2-2b. EM35MR Actuator/3103 Gas Valve/Resolver Outline
(metric electrical conduit entries)
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Figure 2-3a. EM35MR Actuator/3103 Gas Valve 900 psig PED/Resolver Outline
(NPT electrical conduit entries)

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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Figure 2-3b. EM35MR Actuator/3103 Gas Valve 900 psig PED/Resolver Outline
(NPT electrical conduit entries)

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Manual 26734 3103 Gas Valve with EM35MR Actuator
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EM Actuator/3103 Gas Valve Installation
For most applications, the 50 mm (2 inch) flanges when bolted into the system piping can support the
valve/actuator assembly. For applications where this is not practical or where additional support is
required, the assembly can be bolted to a supporting structure by the four 0.625-11 UNC-2B tapped holes
in the valve base.
See Figures 2-1/2-2/2-3 for overall dimensions, installation hole locations, and any fitting or plumbing
connections. Installation attitude does not affect valve/ actuator performance.
Make sure to allow adequate room for required wiring and that the wiring and valve/actuator are
accessible for service.
There are two overboard drains on the 3103 valves (see Figures 2-1/2-2/2-3). One is to be plumbed to an
area outside the turbine enclosure. Use the overboard drain most convenient for your installation and plug
the one that is not used. This drain vents the cavities between the inner and outer seals on both ends of
the valve shaft.
EXPLOSION HAZARD—The overboard drain port vents process fuel
to the atmosphere. The overboard drain gas volume may increase as
temperatures drop below 0 °C (32 °F). Plan the vent system, taking
temperature affects into consideration. Vent the drain ports to a safe
location away from the turbine enclosure or any hazardous location /
explosive atmosphere. Protect the vent line from obstruction,
ph
y
sical dama
g
e, condensation, or corrosion.
Maximum overboard vent pressure is 69 kPa (10 psig). Exceeding
this pressure can potentially damage the valve.
DO NOT plug both drains. This can cause pressure to build up in the
vent cavity and potentially damage the valve.
Recommend placing the end of the line (outside the enclosure) in a
small container of clean, lightweight oil to check for gas leakage.
This will also prevent a corrosive or salt air atmosphere from
corroding the shaft bearings, which are in the cavity between the
shaft seals.
Piping Installation
Refer to ASME B16.5 for details of flange, gasket, and bolt types and dimensions.
The gas fuel control valve is designed for support by the piping flanges alone; additional supports are
neither needed nor recommended.
Verify that the process piping centerline-to-flange-face dimensions meet the requirements of the outline
drawings (Figures 2-1/2-2/2-3) within standard piping tolerances. The valve should mount between the
piping interfaces such that the flange bolts can be installed with only manual pressure applied to align the
flanges. Mechanical devices such as hydraulic or mechanical jacks, pulleys, chain-falls, or similar should
never be used to force the piping system to align with the valve flanges.
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Manual 26734 3103 Gas Valve with EM35MR Actuator
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Use ASTM/ASME SA-449 grade or better bolts or studs to install the valve into the process piping. The
bolt length and diameter for Class 600 flanges shall conform to Table 2-1.
Table 2-1. Class 600 Bolt Length and Diameter
Nominal Pipe
Size
Number of
Bolts
Diameter of
Bolts Stud Length
Machine Bolt
Length
51 mm /
2 inch 8 16 mm / 5/8 inch
108.0 mm /
4.25 inch
88.9 mm /
3.50 inch
Flange gasket materials should conform to ASME B16.20. The user should select a gasket material which
will withstand the expected bolt loading without injurious crushing, and which is suitable for the service
conditions.
When installing the valve into the process piping, it is important to torque the stud/bolts properly in the
appropriate sequence in order to keep the flanges of the mating hardware parallel to each other. Recommend
a two-step torque method. Once the studs/bolts are hand tightened, torque the studs/bolts in a crossing
pattern to half the required torque. After torqueing all studs/bolts to half the appropriate value, repeat the
pattern until obtaining the rated torque value.
Electrical Connections
Improper grounding of the product can result in electric shock or
electrocution. Installation of a protective earth ground at the
provided terminal lu
g
s on the valve is required for safe installation.
Wire and cable installation of the product should take into account
proper cable support or strain relief to prevent stress on the cable or
internal wire connections at the terminals.
Shielded Wiring
All shielded cable must be twisted conductor pairs with either a foil or a braided shield.
Shield all signal lines to prevent picking up stray signals from adjacent equipment.
Connect the shields as shown in the plant-wiring diagram in EM Driver manual 26159. Wire exposed
beyond the shield must not exceed two inches. Leave the other end of the shield open and insulated from
any other conductor.
Do not run shielded signal wires with other wires carrying large currents.
See application note 50532, EMI Control in Electronic Governing Systems, for more information.
Installations with severe electromagnetic interference (EMI) may require shielded cable run in conduit,
double shielded wire, or other precautions. Contact Woodward for more information.
EXPLOSION HAZARD—Do not connect or disconnect while circuit is
live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division or Zone applications.
Explosion Proof / Flame Proof Covers: Do not damage the cover seal,
the cover surface, the threads, or the actuator or resolver surface
while removin
g
or replacin
g
the cover.
Released