Woodward VariStroke-DX User manual

CMM-03013 REV.-
09-22
1
Component Maintenance Manual
Bronze Level
Product Name: VariStroke-DX (VS-DX)
FOR GENERAL DISTRIBUTION
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Table of Contents
1. GENERAL INFORMATION.......................................................................................................................................................................................................7
INTRODUCTION ...............................................................................................................................................................................................................................7
1.1 Regulatory Compliance ....................................................................................................................................................................................................7
1.2 Warnings and Notices ....................................................................................................................................................................................................10
1.3 Electrostatic Discharge Awareness................................................................................................................................................................................12
1.4 Definitions and Used Abbreviations ...............................................................................................................................................................................12
1.5 List of Woodward Literature ...........................................................................................................................................................................................13
1.6 List of Woodward Required Software.............................................................................................................................................................................14
1.7 List of Required Hardware or Materials..........................................................................................................................................................................14
1.8 General Instructions .......................................................................................................................................................................................................16
2. ON-LINE SERVO VALVE REPLACEMENT, VS-DX SKID J-BOX VERSION........................................................................................................................17
2.1 Replacement Kit Description ..........................................................................................................................................................................................17
2.2 VariStroke Servo Disassembly Procedure from VS-DX Skid.........................................................................................................................................20
2.3 VariStroke Servo Installation Procedure on VS-DX Skid ...............................................................................................................................................37
2.4 Appendix 1. Dissasembly Checklist ...............................................................................................................................................................................64
2.5 Appendix 2. Assembly Checklist ....................................................................................................................................................................................65
3. ISOLATION VALVE REPLACEMENT ....................................................................................................................................................................................67
3.1 Replacement Kit Description ..........................................................................................................................................................................................67
3.2 List of Required Hardware or Materials..........................................................................................................................................................................67
3.3 Isolation Valve Removal.................................................................................................................................................................................................68
3.4 Isolation Valve Installation..............................................................................................................................................................................................71
4. SHUTTLE VALVE REPLACEMENT .......................................................................................................................................................................................75
4.1 Replacement Kit Description ..........................................................................................................................................................................................75
4.2 List Of Required Hardware or Materials.........................................................................................................................................................................75
4.3 Shuttle Valve Removal ...................................................................................................................................................................................................76
4.4 Shuttle Valve Installation ................................................................................................................................................................................................79
5. PRESSURE GAUGE REPLACEMENT ..................................................................................................................................................................................81
5.1 Replacement Kit Description ..........................................................................................................................................................................................81
5.2 Pressure Gauge Removal ..............................................................................................................................................................................................82
5.3 Pressure Gauge Installation ...........................................................................................................................................................................................83
6. REVISION HISTORY ..............................................................................................................................................................................................................84
Table of Figures
Figure 2-1. VS-DX Pressure Gauges...................................................................................................................................................................................................20
Figure 2-2. VS-DX Isolation Valves Position........................................................................................................................................................................................21
Figure 2-3. VS-DX J-Box Opening.......................................................................................................................................................................................................22
Figure 2-4. Knife Disconnect Terminal Usage .....................................................................................................................................................................................22
Figure 2-5. Analog Demand Terminals ................................................................................................................................................................................................22
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Figure 2-6. Set Screw in VariStroke Cover ..........................................................................................................................................................................................23
Figure 2-7. VariStroke Cover Opening.................................................................................................................................................................................................23
Figure 2-8. Connecting to RS-232 VariStroke Communication Port....................................................................................................................................................23
Figure 2-9. Disconnecting RS-232 Link ...............................................................................................................................................................................................24
Figure 2-10. Power Terminals Inside VS-DX J-Box.............................................................................................................................................................................24
Figure 2-11. Health Link Terminals Inside VS-DX J-Box.....................................................................................................................................................................25
Figure 2-12. Discrete Outputs, Analog Outputs Terminals Inside VS-DX J-Box .................................................................................................................................25
Figure 2-13. Cable Ties Removal Inside VariStroke............................................................................................................................................................................27
Figure 2-14. Power Connector Placement Inside VariStroke ..............................................................................................................................................................27
Figure 2-15. Signals Connector Placement Inside VariStroke.............................................................................................................................................................28
Figure 2-16. Ground Screw Placement Inside VariStroke ...................................................................................................................................................................28
Figure 2-17. VariStroke Wires Protected with Vinyl Electrical Tape....................................................................................................................................................29
Figure 2-18. PCB Cover Holding Screws Placement Inside VariStroke ..............................................................................................................................................29
Figure 2-19. Actuator Position Sensors Terminals Placement Inside VariStroke................................................................................................................................29
Figure 2-20. VariStroke J-Box Conduit Nut Loosening........................................................................................................................................................................30
Figure 2-21. VariStroke Conduit Nut Loosening ..................................................................................................................................................................................30
Figure 2-22. VariStroke Conduit Fitting Loosening..............................................................................................................................................................................30
Figure 2-23. VariStroke Conduit Rotation ............................................................................................................................................................................................31
Figure 2-24. Wire Pulling from VariStroke ...........................................................................................................................................................................................31
Figure 2-25. PCB Holding Screws Placement Inside VariStroke.........................................................................................................................................................32
Figure 2-26. VariStroke Cover Installation ...........................................................................................................................................................................................32
Figure 2-27. VariStroke Cover Set Screw Installation .........................................................................................................................................................................33
Figure 2-28. Eyebolt Installation...........................................................................................................................................................................................................33
Figure 2-29. VariStroke with Lifting Strap Installed..............................................................................................................................................................................35
Figure 2-30. VariStroke Four Mounting Screws (VS-DX section view)................................................................................................................................................35
Figure 2-31. VariStroke Disconnection ................................................................................................................................................................................................36
Figure 2-32. VariStroke with Supply Piping Disconnected and Plugged Port .....................................................................................................................................36
Figure 2-33. VariStroke with Drain Piping Disconnected and Plugged Port........................................................................................................................................36
Figure 2-34. VariStroke Shipping Plate Removal ................................................................................................................................................................................37
Figure 2-35. Connection Interface Cleaning and O-rings Installation..................................................................................................................................................37
Figure 2-36. Eyebolt Installation...........................................................................................................................................................................................................38
Figure 2-37. VariStroke with Lifting Strap Installed..............................................................................................................................................................................38
Figure 2-38. VariStroke Alignment with VS-DX Manifold.....................................................................................................................................................................39
Figure 2-39. VariStroke Attaching to VS-DX Skid Manifold .................................................................................................................................................................39
Figure 2-40. VariStroke Four Mounting Screws (VS-DX section view)................................................................................................................................................40
Figure 2-41. VariStroke Drain Port Location........................................................................................................................................................................................40
Figure 2-42. VariStroke Supply Port Location......................................................................................................................................................................................40
Figure 2-43. VariStroke Cover Set Screw Location .............................................................................................................................................................................40
Figure 2-44. VariStroke Cover Opening...............................................................................................................................................................................................41
Figure 2-45. Cleaning Conduit Adapter Thread...................................................................................................................................................................................41
Figure 2-46. Wiring Routing for Connection.........................................................................................................................................................................................41
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Figure 2-47. VariStroke Conduit Adapter Installation ..........................................................................................................................................................................42
Figure 2-48. VariStroke J-Box Conduit Nut Tightening........................................................................................................................................................................42
Figure 2-49. Vinyl Electrical Tape Protection Removed From Wires...................................................................................................................................................44
Figure 2-50. VariStroke PCB Cover Screws Location .........................................................................................................................................................................44
Figure 2-51. Actuator Position Sensors Terminals Placement Inside VariStroke................................................................................................................................45
Figure 2-52. Ground Screw Placement Inside VariStroke ...................................................................................................................................................................45
Figure 2-53. VS-DX J-Box Opening.....................................................................................................................................................................................................46
Figure 2-54. Signals Connector Placement Inside VariStroke.............................................................................................................................................................46
Figure 2-55. Power Connector Placement Inside VariStroke ..............................................................................................................................................................46
Figure 2-56. Discrete Outputs and Analog Outputs, Terminals Inside VS-DX J-Box..........................................................................................................................47
Figure 2-57. Knife Disconnect Terminal Usage ...................................................................................................................................................................................47
Figure 2-58. Discrete Outputs, Terminals Remaining Open Inside VS-DX J-Box...............................................................................................................................47
Figure 2-59. Power Terminals Inside VS-DX J-Box.............................................................................................................................................................................48
Figure 2-60. Connecting RS-232 Link..................................................................................................................................................................................................48
Figure 2-61. VS-I Customer Service Tool Home Screen.....................................................................................................................................................................49
Figure 2-62. Settings File Loading to VariStroke .................................................................................................................................................................................49
Figure 2-63. Cylinder Tracking Alarm/Shutdown Configuration...........................................................................................................................................................50
Figure 2-64. Save Values Button Location ..........................................................................................................................................................................................50
Figure 2-65. Alarms/Shutdowns Configuration Page...........................................................................................................................................................................50
Figure 2-66. Alarms/Shutdowns Page .................................................................................................................................................................................................51
Figure 2-67. Redundancy Screen –Air Bleeding Control Screen .......................................................................................................................................................52
Figure 2-68. Air Bleeding Progress Screen .........................................................................................................................................................................................52
Figure 2-69. Servo Air Bleeding Completed ........................................................................................................................................................................................53
Figure 2-70. Run Enable and Reset Status on the Input Configuration Screen..................................................................................................................................54
Figure 2-71. Analog Demand Terminals ..............................................................................................................................................................................................55
Figure 2-72. Input Configuration Screen..............................................................................................................................................................................................55
Figure 2-73. Redundant Feedback Pulse Error on the Alarms/Shutdowns Screen ............................................................................................................................56
Figure 2-74. Health Link Terminals Inside VS-DX J-Box.....................................................................................................................................................................56
Figure 2-75. Redundancy Screen and Alarm/Shutdown Annunciation ...............................................................................................................................................57
Figure 2-76. Discrete Outputs Terminals Inside VS-DX J-Box ............................................................................................................................................................58
Figure 2-77. Health Link Terminals Inside VS-DX J-Box.....................................................................................................................................................................58
Figure 2-78. Alarms and Shutdowns Screen .......................................................................................................................................................................................59
Figure 2-79. Feedback Readings on the Input Configuration Screen..................................................................................................................................................60
Figure 2-80. Terminating Connection to the VariStroke ......................................................................................................................................................................60
Figure 2-81. VS-DX J-Box Closing ......................................................................................................................................................................................................61
Figure 2-82. Disconnecting RS-232 Link .............................................................................................................................................................................................61
Figure 2-83. VariStroke Eyebolt Removal............................................................................................................................................................................................61
Figure 2-84. VariStroke Cover Installation ...........................................................................................................................................................................................62
Figure 2-85. VariStroke Cover Set Screw Location .............................................................................................................................................................................62
Figure 2-86. VS-DX Isolation Valves Position......................................................................................................................................................................................62
Figure 3-1. VariStroke Isolation Valves................................................................................................................................................................................................68
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Figure 3-2. VariStroke Isolation Valves in Horizontal Position.............................................................................................................................................................68
Figure 3-3. Isolation Valve Bracket Retaining Screw Location............................................................................................................................................................69
Figure 3-4. Isolation Valve Locking Bracket Repositioning..................................................................................................................................................................69
Figure 3-5. Isolation Valve Removal ....................................................................................................................................................................................................70
Figure 3-6. Isolation Valve Bracket Retaining Screw Location............................................................................................................................................................71
Figure 3-7. Isolation Valve Locking Bracket Repositioning..................................................................................................................................................................71
Figure 3-8. Isolation Valve Mating Surfaces Cleaning.........................................................................................................................................................................72
Figure 3-9. Isolation Valve Seals .........................................................................................................................................................................................................72
Figure 3-10. Isolation Valve Mating Surfaces Cleaning.......................................................................................................................................................................73
Figure 3-11. Isolation Valve Tightening Sequence ..............................................................................................................................................................................73
Figure 3-12. VariStroke Isolation Valves in Horizontal Position...........................................................................................................................................................74
Figure 3-13. Locking Bracket Installation.............................................................................................................................................................................................74
Figure 4-1. VariStroke Isolation Valves in Vertical Position (isolating) ................................................................................................................................................76
Figure 4-2. VariStroke Isolation Valves Control Port Location.............................................................................................................................................................76
Figure 4-3. VariStroke Shuttle Valve Retaining Screws ......................................................................................................................................................................77
Figure 4-4. VariStroke Shuttle Valve Removal ....................................................................................................................................................................................77
Figure 4-5. Shuttle Valve Locating Pin.................................................................................................................................................................................................78
Figure 4-6. Shuttle Valve Locating Pin in VS-DX Manifold ..................................................................................................................................................................78
Figure 4-7. Shuttle Valve and VS-DX Mating Surfaces Cleaning........................................................................................................................................................79
Figure 4-8. Shuttle Valve Installation Screws ......................................................................................................................................................................................80
Figure 4-9. O-rings Installation into Shuttle Valve Manifold.................................................................................................................................................................80
Figure 4-10. Shuttle Valve Installation .................................................................................................................................................................................................80
Figure 5-1. Needle Valve Closing ........................................................................................................................................................................................................82
Figure 5-2. Pressure Gauge and Adapter Installation / Removal ........................................................................................................................................................82
Figure 5-3. Assembling Gauge Coupling .............................................................................................................................................................................................83
Figure 5-4. Needle Valve Opening.......................................................................................................................................................................................................83
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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
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 get the latest copy.
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 any resulting damage, and (ii) invalidate product certifications or listings.
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1. GENERAL INFORMATION
INTRODUCTION
This Component Maintenance Manual is intended to be used by customers and Woodward authorized service centers for repair or service of the VariStroke-DX
(VS-DX). Bronze level service is preventative and routine maintenance requiring little to no specialized tooling, testing, or calibration procedures to maintain
product between normal overhaul intervals. This manual is written with the assumption that the reader has access to the product manual and other Woodward
literature referenced within this document.
1.1 Regulatory Compliance
The VS-DX is subject to safety regulatory certifications. See product manual 35132 for additional details. The service center performing the work on the VS-DX
must not alter the construction such that the certifications are invalidated.
FLAMEPATH
Disassembly of product will require handling of critical components used in a Zone 1 Flameproof and/or Division 1
Explosion-proof design. Special care must be taken to not damage these parts as it could compromise the protection
method for the product. Flamepaths are identified in drawing 9989-7006.
Threaded Flamepaths: Care must be taken during handling and assembly to not damage threads. Inspect for damage to threads, including but not limited to,
galling, cross threading, and excessive wear. Damage to threads and/or thread fit can compromise the effectiveness of the protection method. If any damage is
discovered, contact Woodward prior to reinstallation or assembly into system.
Radial and Flat Joint Flamepaths: Care must be taken during handling and assembly to not damage the flat surface of the flamepath. Inspect primary surface
and mating surface for damage, including but not limited to, scratches, porosity, and marks due to impact. Damage to these surfaces can compromise the
effectiveness of the protection method. If any damage is discovered, contact Woodward prior to reinstallation or assembly into system.
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Safety Symbols
Direct current
Alternating current
Both alternating and direct current
Caution, risk of electrical shock
Caution, refer to accompanying documents
Protective earth terminal
Frame or chassis terminal
!
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The following flamepaths have a maximum constructional gap (ic) less than that required by Tables 1 and 2 of EN 60079-1:
Flame Path
Max Gap, ic (mm)
Min. Width of Joint L (mm)
Spool to Spacer
0.079
13.46
Sleeve to Spacer
0.079
12.85
Sleeve to Sleeve
0.048
14.76
Sleeve to Housing
0.076
15.85
Sensor to Plate
0.08
36.25
Plate to Housing
0.10
22.91
Plate to Housing
0.10
20.22
Plate to Plate
0.10
22.91
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 2 applications.
Do not to damage the cover seal, cover surface, threads, or the VS-I surface while removing or replacing the cover. Damage
to sealing surfaces may result in moisture ingress, fire, or explosion. Clean the surface with Isopropanol if necessary.
Inspect the cover joint surfaces to ensure that they are not damaged or contaminated.
For Division 1/Zone 1 products: Proper torque on all joints is critical to ensure that the unit is sealed properly.
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1.2 Warnings and Notices
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.
1. DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
2. WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious injury.
3. CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate injury.
4. NOTICE - Indicates a hazard that could result in property damage only (including damage to the control).
5. IMPORTANT - Designates an operating tip or maintenance suggestion.
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 working fluid(s) and comply with recommended safety
equipment.
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Disconnect
Power Supply
Before performing maintenance, always disconnect power and any hazardous voltages that may be connected. Follow all
appropriate lockout-tagout procedures.
Hazards due to insufficiently qualified personnel!
If unqualified personnel perform work on or with the product, hazards may arise which can cause serious injury and
substantial damage to property. Therefore, all work must be carried out by appropriately qualified personnel.
Remove pressure before servicing. Failure to do so may damage the VS-DX and/or cause injury.
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1.3 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 since these materials do not store static electric charges as much as synthetics.
2. If you must open the VariStroke housing cover, follow these precautions:
•Do not touch any part of the PCB.
•Do not touch the electrical conductors, connectors, or components with conductive devices or with your hands.
1.4 Definitions and Used Abbreviations
CCW
–Counter Clockwise
CMM
–Component Maintenance Manual
Control System
–Digital system that controls and monitors the VariStroke(s) turbine governor or
Distributed Control System (DCS)
CW
–Clockwise
In Control
–The unit controlling the position of the servo system
Master / Slave
–The unit designated as the Master yields control to the other unit (Slave) through a
link between the two VS’s. The unit designated as the Master will take control during
VS-DX startup.
Not In Control
–The unit acting as the backup to the In Control unit
VS
–VariStroke-I Servo
VS-DX
–VariStroke Duplex Hydraulic Servo Skid
VS-GI
–VariStroke-I GI Single Acting Servo
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1.5 List of Woodward Literature
Manual 26455 –
Customer Publication Cross Reference and
Revision Status & Distribution Restrictions
Product Manual 35119 –
VariStroke-GI (VS-GI) Electro-hydraulic
Actuator
Product Manual 35132 –
VariStroke-DX Duplex Hydraulic Servo Skid
Manual 35148 -
Customer Service Tool for VariStroke-I
(VS-I, VS-GI, and VS-DX)
Electro-hydraulic Actuator and Servo
Manual 82715 –
Guide for Handling and Protection of Electronic
Controls, Printed Circuit Boards, & Modules
Download Woodward Material: (www.woodward.com).
Required Drawings
Reference Kit Number
Installation Drawing 9999-1852
VariStroke-DX Duplex Hydraulic Servo Skid
N/A
Installation Drawing 9989-7006
FLAMEPATH, VARISTROKE I
N/A
Installation Drawing 9999-1897-2
Kit, VS-GI REPLACEMENT, J-BOX, FAIL EXTEND, FOR VS-DX SKID
8935-1341
Kit, VS-GI REPLACEMENT, J-BOX, FAIL RETRACT, FOR VS-DX SKID
8935-1343
Installation Drawing 9999-1897-3
Kit, REPLACEMENT ISOLATION VALVE, RIGHT HAND, FOR VS-DX SKID
8935-1338
Kit, REPLACEMENT ISOLATION VALVE, LEFT HAND, FOR VS-DX SKID
8935-1339
Installation Drawing 9999-1897-4
Kit, PRESSURE GAUGE, FOR VS-DX SKID
8935-1344
Installation Drawing 9999-1897-5
Kit, SHUTTLE VALVE, FOR VS-DX SKID
8935-1336
If unable to access Woodward documentation, refer to contact list at the end of this manual.
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1.6 List of Woodward Required Software
9927-2177
VS-I Customer Service Tool
Locate the installation program within Woodward’s software download page by searching for "9927-2177" on www.woodward.com/software. The installation
manual is provided within manual 35148 Customer Service Tool for VariStroke-I.
If the appearance or operation of the Customer Service Tool software
differs from the description and screenshots in this document,
please refer to the latest Customer Service Tool manual 35148.
1.7 List of Required Hardware or Materials
Torque wrench(es)
(required torque range
during installation)
Required torque ranges, wrench end type, and sizes for installation
•90.0 –110.0 LBFT (122 –149 Nm), Type: open end; Size: 2 1/4 in
•56.0 –68.0 LBFT (76 –92 Nm) Hex bit socket, Type: open end; Size: 1 13/16 in
•100.0 –128.0 LBFT (136 –174 Nm), Type: open end; Size: 1 1/2 in
•40.0 –60.0 LBFT (61 –75 Nm), Type: socket head; Size: 3/4 in
Wrench(es)
•Type: Allen wrench ; Size: 1.5 mm
•Type: socket head; Size: 2 1/4 in
•Type: open end; Size: 1 13/16 in
•Type: open end; Size: 1 1/2 in
•Type: open end; Size: 3/4 in
•Type: open end; Size: 13/16 in
•Type: open end; Size: 1 3/8 in
Torque Screwdriver(s)
Installation required torques range, screwdriver end type, and size
•5.3 -7.0 LBIN (0.6-0.8 Nm), Type: slotted; Tip Size: 3.5 X 0.6 mm
•11.0 –13.0 LBIN (1.2 –1.5 Nm), Type: Philips; Tip Size: PH2
•45 LBIN (5.1 Nm), Type: Philips; Tip Size: PH2
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Screwdriver(s)
•Type: slotted; Tip Size 5.5 X 0.8 mm
•Type: slotted; Tip Size 3.5 X 0.6 mm
•Type: Philips; Tip Size: PH2
•Type: Philips; Tip Size: PH0
•Type: slotted; 2.5 mm x .4 mm
Others
•RS-232 straight-through serial cable (male connector- both ends)
•Multimeter
•Cable sleeving 3/4" (e.g., PTN0.75BK75) / foil and insulation tape
•Cable ties approx. 8 inch (200 mm) long
•Oil absorbent pads / mats
•Lifting strap (minimum weight capacity 100 lbs / 50 kg)
•Cable tie removal tool
•PC computer with Woodward VS-I Customer Service Tool installed
•Isopropyl alcohol
•Petroleum jelly
•Loctite 592 thread sealant
•Parker Super O-Lube or similar
•Lifting eye (minimum weight capability 100 lbs / 50 kg),
thread size .500-13
•Parameterization .wset file as backup for the VS unit to be replaced - can be skipped if unit to
be replaced is operable and can communicate via Customer Service Tool
Tools are not contained within the replacement kit. Please order separately.
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1.8 General Instructions
•Lifting:
oFor proper and safe lifting instructions and diagrams, see product manual 35132.
•Review this CMM and the installation drawing before starting the replacement procedure to be sure that all necessary tools are available, and
instructions are clear. Check the replacement parts kit to verify all replacement parts listed in the installation drawing are present. Sort all parts for easy
assembly. For questions, contact Woodward.
•If not all the parts are used, the unit or units must be inspected for completeness.
•Contact Woodward if an error is found during the replacement process.
•Clean the exterior of the VS-DX prior to disassembly to prevent dirt and debris from contaminating the unit interior.
•O-rings:
oUse the correct tool to install or remove O-rings. If using a protective cone on small O-rings, lubricate the O-ring and slide it on to the part, being
sure it does not twist.
oIf a cone is not used on large O-rings, use a pick under the O-ring to lift it onto the part until it is in the desired location.
•Helical inserts:
oTo prevent damage to mid-grip helical inserts, install screws at a slow speed. DO NOT USE A HIGH-SPEED TOOL. Stainless steel screws
MUST be lubricated with an anti-seize lubricant before turning them into mid-grip helical inserts or aluminum parts.
•Disassembly:
oParts that have been disassembled and will be reused must be inspected closely for damage and replaced if necessary. Parts that have been
disassembled should be kept in a clean container such that they can be readily identified using this procedure, reference drawings, or visual aids
for proper reassembly.
•Bolts and Screws:
oAll screws and bolts loosen with counterclockwise (CCW) direction. In other situations, the direction will be specified.
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2. ON-LINE SERVO VALVE REPLACEMENT, VS-DX SKID J-BOX VERSION
It is recommended that one person observes turbine operation while the servo replacement is in progress. This person
would be able to react quickly if there is interference with turbine operation during replacement.
2.1 Replacement Kit Description
The purpose of this procedure is to show the correct sequence and method of servo replacement (VS-DX with J-Box version):
Servo Valve Replacement:
KIT P/N
Installation Drawing
8935-1341 –Kit, VS-GI REPLACEMENT, J-BOX, FAIL EXTEND, FOR VS-DX SKID
9999-1897-2
8935-1343 –Kit, VS-GI REPLACEMENT, J-BOX, FAIL RETRACT, FOR VS-DX SKID
Review this CMM and installation drawing before starting the replacement procedure to be sure that all necessary tools
are available and everything is clear. For any questions, contact Woodward.
For safety reasons, this procedure requires at least two operators due to risk of turbine overspeed, injury from heavy lifting, and leaking oil.
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On-Line Modification,
Reconfiguration or Start-Up
The settings on the VS-GI servos must be precisely matched prior to engaging in concurrent
“live” (on-line) operation or “live” transition between servos on an end application. Failure to
precisely match and tune the configuration of servos to the proper control range prior to
engaging in a “live” (on-line) replacement could result in turbine overspeed, loss of control,
plant shutdown, property damage, and severe bodily injury, including death.
Proper servo configuration and dynamic settings are unique to specific end applications. It is
the responsibility of the end user to determine the specific configuration and dynamic settings
necessary for each specific servo application. This VS-GI unit replacement procedure is a
guideline that is dependent upon user-supplied configuration and dynamic setting data.
Because of the variability of end applications, Woodward makes no warranty, expressed or
implied, as to the suitability of this procedure for any given “live” installation.
End users must develop site procedures suitable for specific end applications and ensure that
personnel are fully trained on such procedures prior to attempting to replace a servo on a “live”
running turbine. All safety protective systems (overspeed, over temperature, overpressure,
etc.) must be in proper operational condition prior to the start of an on-line replacement
procedure. Personnel should be equipped with appropriate personal protective equipment to
minimize the potential for injury due to release of hot hydraulic fluids, exposure to hot surfaces,
and/or moving parts located near the VS-GI.
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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.
Before starting to disassemble, make sure that VS-GI settings file back-up is created on
a fully functional unit that has been previously tuned using the Customer Service Tool
software. Download and save a .wset file in a safe storage in a place where you can find
it for later use.
FLAMEPATHS - Refer to Section 1.1 for specific instructions.
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2.2 VariStroke Servo
Disassembly Procedure from
VS-DX Skid
1. Confirm that the servo to be withdrawn is
designated as the Slave.
a) Control system commands to the
withdrawn servo to be designated Slave
[notate result in Checklist: ID #1].
b) Feedback in control system indicates
the withdrawn Servo is NotInControl
[notate result in Checklist: ID #2].
c) Pressure reading on the withdrawn
servo’s gauge is 0 bar (Figure 2-1)
[notate result in Checklist: ID #3].
Figure 2-1. VS-DX Pressure Gauges
Before proceeding with the replacement procedure,
print Appendix 1. Disassembly Checklist and
Appendix 2. Installation Checklist.
Notate the disassembly and installation results at
each checkpoint.
The procedure below provides instructions
exclusively for replacing either Servo A or Servo B.
The instructions are differentiated by color.
To replace Servo A, use directions in Red only.
To replace Servo B, use directions in Blue only.
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