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 Out-of-date translations are marked with .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
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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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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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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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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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DVP Specifications
The ELA requires the DVP10000. Refer to DVP 5000/10000/12000 manual 26773 for specifications and
additional information on the operation and configuration of the DVP 10000.
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Chapter 3.
Installation Requirements
Introduction
External Fire
Protection
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.
Explosion Hazard
Do not connect/disconnect electrical connectors unless power has
been switched off or the area is known to be non-hazardous.
Hearin
g
Protection
Due to typical noise levels in turbine (or engine) and environments,
wear hearing protection when working on or around the ELA.
This chapter provides the general information for mounting location selection, installation, and wiring of
the ELA actuator. For DVP10000 installation instructions, see the DVP 5000/10000/12000 manual 26773.
Mechanical Installation Requirements
Unpacking
Use care when unpacking the ELA. Abuse can damage seals, installation surfaces, and factory
adjustments. Notify the shipper and Woodward if damage is found.
Check for and remove all manuals and other items before discarding the shipping crate.
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Lifting Procedures
Lifting procedures for vertical, inverted and motor lifts follow:
Vertical Lift
A vertical lift is accomplished by following the steps below:
1. Install one lifting strap or cable through rod end
2. Lift the ELA
Figure 3-1. Vertical Lift Example
Inverted Lift
An inverted lift is accomplished by following the steps below:
1. Install one lifting strap or cable through clevis
2. Lift the ELA
Figure 3-2. Inverted Lift Example
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Motor Lift
A motor lift is accomplished by following the steps below:
1. Install one lifting strap or cable around the motor of the ELA
2. Lift the ELA
Figure 3-3. Motor Lift Example
Un-Approved Lift
Do not place any force or lift by the LVDT Housing, LVDT Rod, LVDT
Cover, or LVDT Clamp Arm. Damage will occur if lifted at these
locations.
Figure 3-4. Unapproved Lifting Example
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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Instalation Drawing
Figure 3-5a. ELA 150 Base Mount Dimensions
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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Figure 3-5b. ELA 150 Base Mount Dimensions
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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Figure 3-5c. ELA 150 Base Mount Dimensions
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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Turnbuckle Function
The rod end can be adjusted by loosening both jam nuts and turning the center turnbuckle. Turning the
center turnbuckle will extend and retract the rod end. The overall length can be adjusted +/-1 inch from
the nominal position.
Figure 3-6. Position and Adjust Turnbuckle
Turnbuckle Tightening
1. First torque the larger jam nut to 500 FT-LBS
2. Next torque the smaller jam nut next to 400 FT-LBS
Figure 3-7. Secure Turnbuckle Jam Nuts
Turnbuckle Lockwire
1. Lockwire the nuts in place through the provided holes. See figure below.
Note: The lower jam nut is a left-hand thread, and the upper jam nut is a right-hand thread. Ensure
lockwire is done in the correct direction to prevent loosening.
The reaction torque from the torque wrench must be supported by a
second wrench on the provided flats directly below the jam nuts.
Failure to do so could dama
g
e the actuator.
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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount
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Figure 3-8. Lockwire Nuts
Manual Drive Access Plug
The actuator can be mechanically stroked and aligned to a mechanical position by use of a manual drive.
1. To access the drive first remove the manual drive access plug below the motor per the image below.
2. After removing the plug, rotate the gear train by inserting a 0.75" hex drive and turning the motor and
pinion gear to the desired position.
Note: The extended and retracted internal mechanical hard stops can be found by turning the drive until it
stopes when 2.5 ft-lbs is applied. The actuator drive should rotate and move the shaft with less than
1.5 ft-lbs applied to the drive. Do not apply more than 10 ft-lbs to this drive or damage can occur to the
actuator. The 0% electrical position is set 1 motor turn away from the hard stop position (where the hard
stop position is measured at 2.5 ft-lbs).
3. Replace the manual drive access plug when you are finished.
Figure 3-9. Manual Drive Access Plug Location
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Figure 3-10. Manual Drive Rotation Example
Do not connect power to the actuator until the hand tool has been
removed from the manual drive port and the plug replaced per these
instructions. Serious personal injury may result from access to moving
parts while actuator is powered.
Electrical Installation Requirements
DVP10000
Instructions
Refer to DVP10000 manual 26773 for critical installation instructions
and warnings that may pertain to EMC or Hazardous Locations
certifications. The following instructions are specific to this actuator
only and are meant as a supplement to the general DVP10000
instructions. Failure to do so may result in poor performance, personal
in
j
ur
y
, or death.
Install the motor power cable, motor resolver cables, and ID Module cable in accordance with the figures
in the below wiring section. Fully tighten (by hand) all mating electrical connectors on the ELA. Loose or
cross-threaded connectors may lead to poor electrical connection and impair the IP rating listed in the
specification section.
Shielding Requirements
See DVP 5000/10000/12000 manual 26773.
Cables
Prefabricated cables from Woodward can be used, or the customer can manufacture cables to the same
standards. The figures below show the cable requirements and Woodward part numbers. Contact
Woodward for other cable configuration availability (connectors on both ends, either straight or 90-degree
backshell options).
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