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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