Woodward ELA 150 User manual

Product Manual 35183
(Revision -, 5/2022)
Original Instructions
Electric Linear Actuator (ELA)
ELA 150 Base Mount
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.
To verify that you have the latest revision, check manual
26455 , Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
the publications page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If
your publication is not there, please contact your customer service representative
to receive the latest cop
y
.
Proper Use
Any unauthorized modifications to or use of this equipment outside of 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
an
y
resultin
g
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. Be sure to check manual
26455 , Customer Publication
Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
Revisions— A bold, black line alongside the text identifies changes in this publication since the
last revision.
The following are trademarks of Woodward, Inc.:
ProTech
Woodward
The following are trademarks of their respective companies:
Modbus (Schneider Automation Inc.)
Pentium (Intel Corporation)
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 35183
Copyright © Woodward, Inc. 2022
All Rights Reserved
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
Woodward 1
Contents
WARNINGS AND NOTICES ............................................................................................................... 3
ELECTROSTATIC DISCHARGE AWARENESS...................................................................................... 4
REGULATORY COMPLIANCE ............................................................................................................ 5
CHAPTER 1. GENERAL INFORMATION .............................................................................................. 7
CHAPTER 2. SPECIFICATIONS.......................................................................................................... 8
DVP Specifications........................................................................................................................................ 9
CHAPTER 3. INSTALLATION REQUIREMENTS .................................................................................. 10
Introduction ................................................................................................................................................. 10
Mechanical Installation Requirements ........................................................................................................ 10
Electrical Installation Requirements............................................................................................................ 18
Installation and Commissioning Checks ..................................................................................................... 25
CHAPTER 4. PC SERVICE TOOL OPERATION ................................................................................. 26
CHAPTER 5. SET-UP AND OPERATION ........................................................................................... 27
Setting up the DVP and ELA....................................................................................................................... 27
Pre-start and Operational Checks............................................................................................................... 28
CHAPTER 6. DIAGNOSTICS............................................................................................................ 29
CHAPTER 7. MAINTENANCE AND HARDWARE REPLACEMENT......................................................... 30
Maintenance................................................................................................................................................ 30
CHAPTER 8. PRODUCT SUPPORT AND SERVICE OPTIONS .............................................................. 32
Product Support Options............................................................................................................................. 32
Product Service Options ............................................................................................................................. 32
Returning Equipment for Repair ................................................................................................................. 33
Replacement Parts...................................................................................................................................... 34
Engineering Services .................................................................................................................................. 34
Contacting Woodward’s Support Organization ........................................................................................... 34
Technical Assistance .................................................................................................................................. 35
CHAPTER 9. LONG-TERM STORAGE REQUIREMENTS ..................................................................... 36
REVISION HISTORY ....................................................................................................................... 37
DECLARATIONS ............................................................................................................................ 38
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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Illustrations and Tables
Figure 3-1. Vertical Lift Example................................................................................................................. 11
Figure 3-2. Inverted Lift Example................................................................................................................ 11
Figure 3-3. Motor Lift Example.................................................................................................................... 12
Figure 3-4. Unapproved Lifting Example .................................................................................................... 12
Figure 3-5a. ELA 150 Base Mount Dimensions.......................................................................................... 13
Figure 3-5b. ELA 150 Base Mount Dimensions.......................................................................................... 14
Figure 3-5c. ELA 150 Base Mount Dimensions.......................................................................................... 15
Figure 3-6. Position and Adjust Turnbuckle ................................................................................................ 16
Figure 3-7. Secure Turnbuckle Jam Nuts ................................................................................................... 16
Figure 3-8. Lockwire Nuts ........................................................................................................................... 17
Figure 3-9. Manual Drive Access Plug Location......................................................................................... 17
Figure 3-10. Manual Drive Rotation Example............................................................................................. 18
Figure 3-11. Motor Power Cable................................................................................................................. 20
Figure 3-12. Motor Power Cable................................................................................................................. 21
Figure 3-13. DVP Integrated Signal Cable.................................................................................................. 22
Figure 3-14. DVP Integrated Signal Cable.................................................................................................. 23
Figure 3-15. Control Wiring Diagram .......................................................................................................... 24
Table 2-1. ELA 150 Specifications................................................................................................................ 8
Table 3-1. Installation Checklist (Before Power is Applied to the System)................................................. 25
Table 3-2. Pre-operational Checklist (Before Stroking the Actuator).......................................................... 25
Table 5-1. Installation, Pre-operational, Pre-start, and Operational Checks .............................................. 28
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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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 completely independent 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 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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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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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, 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. After removing the old PCB from the control cabinet, immediately
place it in the antistatic protective bag.
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking
ATEX – Potentially
Explosive
Atmospheres
Directive:
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 2: II 3 G, Ex ec IIC T3 Gc
EMC Directive Declared to Directive 2014/30/EU of the European Parliament and of the
Council of 26 February 2014 on the harmonization of the laws of the
Member States relating to electromagnetic compatibility (EMC).
Other European Compliance:
Compliance with the following European Directives or standards does not qualify this product for
application of the CE Marking:
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.
ATEX Directive: Exempt from the non-electrical portion of the ATEX Directive 2014/34/EU
due to no potential ignition sources per EN ISO 80079-36:2016 for Zone 2
installation.
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.
Other International Compliance:
IECEx Certified for use in hazardous locations
IECEx CSA 15.0032X Ex ec IIC T3 Gc
North American Compliance:
These listings are limited only to those units bearing the CSA mark.
CSA: CSA Certified for Class I, Division 2, Groups A, B, C, & D, T3 at 121 °C
A
mbient. For use in Canada and the United States. Certificate 70010175
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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Explosion Hazard
Do not remove covers or connect/disconnect electrical connectors
unless power has been switched off or the area is known to be non-
hazardous.
Substitution of components may impair suitability for Class I, Division
2, or Zone 2 applications.
Risque d'explosion
Ne pas enlever les couvercles, ni raccorder / débrancher les
prises électriques, sans vous en assurez auparavant que le
système a bien été mis hors tension; ou que vous situez
bien dans une zone non explosive.
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I, Division 2
et/ou Zone 2.
Special Conditions for Safe Use
Wiring must be in accordance with North American Class I, Division 2, or European or other international
Zone 2, Category 3 wiring methods as applicable, and in accordance with the authority having jurisdiction.
Use supply wires suitable for at least 10°C above surrounding ambient.
Note: Cables supplied through Woodward meet this requirement.
To assure IP55 ingress protection, attach mating connectors to the actuator’s receptacles
Compliance with the Machinery Directive 2006/42/EC noise measurement and mitigation requirements is
the responsibility of the manufacturer of the machinery into which this product is incorporated.
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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Chapter 1.
General Information
The ELA actuation system consists of an electronically controlled linear actuator and a digital electronic
positioner for position control on industrial turbine applications. The digital positioner and actuator
combination are capable of precisely positioning the actuator to follow the setpoint signal from the turbine
control system. The actuator position is controlled by regulating the current to a 3-phase brushless DC
motor, which converts the rotary motion to linear motion via a gear reduction system and leadscrew.
Redundant resolver rotary position transducers are used to sense motor shaft position for commutation
and velocity feedback to the digital positioner. Should one resolver fail, the positioner will revert to the
working sensor to maintain operation.
The Woodward Electric Linear Actuator (ELA) includes the following major sub-assemblies:
A high reliability brushless DC motor
A high load capacity roller screw, driven by a spur gear train
Dual motor resolvers for motor commutation and primary position feedback
An LVDT for independent shaft positioning verification
The Woodward ELA design offers the following benefits to the purchaser in comparison to other electric
actuators:
The actuator and model-based controller provide the accuracy, bandwidth and slew times required for
precise control of the guide vanes. No dynamic tuning is necessary during installation or operation.
The highly capable electronic positioner provides comprehensive diagnostic and communication
functions. These features minimize installation and replacement times and improve system
maintainability.
The Woodward actuator is designed to provide high force consistent with heavy industrial equipment.
All power train and electronic components are designed with conservative design margins for high
reliability. The simple and robust design is capable of consistent performance for extended periods in
challenging environments.
The actuator and digital positioner have been designed to achieve extended Mean Time Between
Overhaul (MTBO) goals. These targets have been reached through the conservative rating of parts
and the careful analysis of individual component and system performance.
An integrated Identification Module (ID module) comes in each actuator. This ID module provides key
information specific to the actuator assembly (i.e., identifies the stroke, gear ratio, motor
characteristics, and device startup limits.) The digital positioner electronically queries the ID module
every time it is powered up. This provides for quick and error free initialization of a new actuator or
digital positioner.
The electronic position controller provides for dual power inputs, and options for redundant digital
interfaces for improved reliability.
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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Chapter 2.
Specifications
Table 2-1. ELA 150 Specifications
T
y
pe Electric Mechanical Actuator
(
EMA
)
Dut
y
C
y
cle Continuous
Stroke Ranges Available (max): 2.000 inch stroke
3.000 inch stroke
Peak Force
(
0.5 seconds
)
* 160 kN / 36 000 lb. bidirectional
Stall Force
(
continuous
)
* 160 kN / 36 000 lb. bidirectional
Continuous Application Force * 105 kN / 24 150 lb. bidirectional
Speed under Opposing Load 2 in: 0.4 in/sec
3 in: 0.6 in/sec
Max Speed @ Zero Force 2 in: 0.4 in/sec
3 in: 0.6 in/sec
Max Motor Input Current 25 A continuous
Input Voltage (to DVP10000) 112–300 VDC absolute min/max 125 Vdc typical
(
see manual 26773
)
Input Current (to DVP10000) –
Max Stead
y
State1:
2.5 Amps at 15,000 lbf
4.5
A
mps at 30,000 lbf
Input Current (to DVP10000) –
Max Transient2: 40 Amps for 5 seconds
Accurac
y
≤±1.0% of full scale
Repeatabilit
y
Ran
g
e Within ± 0.5% of full scale
D
y
namic Bandwidth > 2 Hz at
–
3 dB 90 de
g
rees phase loss
Design Life
20 years with overhauls
96,000 hours overhaul period recommended
Lubrication required ever
y
3
y
ears
MTBF 122,550 hours with 90% confidence at rated load with 2 Hz ± 2 mm
noise and annual maintenance includin
g
driver
Fail-safe Actuation Position to 0% on loss of demand si
g
nal
Normal Ambient Operating
Temperature –18 to +121 °C / 0 to +250 °F
Rated Ambient Operating
Temperature –40 to +121 °C / –40 to +250 °F
Stora
g
e Ambient Temperature
–
40 to +121 °C /
–
40 to +250 °F
Rated Operatin
g
Elevation 3000 m
(
10 000 ft.
)
max
IP Ratin
g
(
per IEC 60529
)
IP55
Vibrations (validation) Random vibration per Mil-STD 810F, M514.5 Category 22,
level/duration 2.3.11 Fi
g
ure 514.5C-16.
Vibrations (shock) US MIL-STD 810F, Method 516.5, Procedure 1. 10 G Peak, 11 ms
duration sawtooth pulse
Envelope and Mountin
g
See installation drawin
g
s and fi
g
ures below
Actuator Wei
g
ht 586 lbs
* Actuator output forces will be reduced below normal ambient operating temperature range due to increased grease
viscosity at cold temperatures.
** Dynamic performance can be influenced by the customer filter settings. Values assume additional customer
settings are turned off.
1Assumes slow modulation when following a base load. Does not consider additional power required as
seen in grid firming applications requiring continuous and fast ramping of power. If this is expected in the
application, please contact Woodward for additional information.
2Information provided for breaker and wire sizing. Input current required when performing a full 100%
step at the continuous application force.
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