Woodward VariStroke-I Product Manual
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Woodward VariStroke-I Product Manual

Electro-hydraulic actuator
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Released
Product Manual 26727
(Revision R, 1/2020)
Original Instructions
VariStroke-I (VS-I)
Electro-hydraulic Actuator
Installation and Operation Manual

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Summary of Contents for Woodward VariStroke-I

  • Page 1 Released Product Manual 26727 (Revision R, 1/2020) Original Instructions VariStroke-I (VS-I) Electro-hydraulic Actuator Installation and Operation Manual...
  • Page 2 Revisions— A bold, black line alongside the text identifies changes in this publication since the last revision. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    Installation Instructions ..........................34 4. S .................. 57 HAPTER ERVICE NSTALLATION System Requirements ..........................57 Setup ................................57 Installing the VariStroke-I Service Tool ....................... 58 Connecting to the VariStroke-I ........................62 5. C ................63 HAPTER ALIBRATION AND ONITORING Introduction..............................63 System Information .............................
  • Page 4 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator 9. A ......96 HAPTER SSET ANAGEMENT AND EFURBISHMENT CHEDULING ERIOD 10. L ..............97 HAPTER TORAGE EQUIREMENTS ..........98 PPENDICES UTLINE RAWINGS AND NSTALLATION EATURES Appendix A – V45 Servo, 4-inch (100mm) Bore Integrated Servo-Cylinder (V45TD-10XX) ...... 99 Appendix B –...
  • Page 5 Figure 1-3. Hydraulic Power Cylinder - Stroke Adjustment Options ............16 Figure 1-4. Application Example ......................... 17 Figure 1-5. VariStroke-I Remote Servo, Key Features ................19 Figure 1-6. Nomenclature and Ordering Number Encoder ................. 20 Figure 2-1. VSI Maximum Transient Flow Rates (During Full Slew) ............24 Figure 2-2.
  • Page 6 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 6-1. Input Configuration Screen ....................... 74 Figure 6-2. Output Configuration Screen ....................76 Figure 6-3. Advanced Configuration Screen ....................78 Figure 6-4. Linearization Screen ......................... 79 Figure 6-5. Alarms and Shutdowns Screen ....................80 Figure 6-6.
  • Page 7 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Table RC-1. Linear Electro-Hydraulic Actuator, Model VariStroke-I ............10 Table 2-1. Bore and Rod Diameter by Valve Size ..................21 Table 2-2. Available Springs for Spring Assist Cylinders ................21 Table 2-3. Environmental Specifications ..................... 22 Table 2-4.

  • Page 8: Warnings And Notices

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator 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.

  • Page 9: Electrostatic Discharge Awareness

    • 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.

  • Page 10: Regulatory Compliance

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Regulatory Compliance Product Compliance Code: Product certifications are dictated by the product model number, and traceable per the product serial number. For information on which hazardous locations any particular VariStroke is rated for, refer to the Model Number and Model Number information below. Find the Model Number on the nameplate of the VariStroke.
  • Page 11 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...
  • Page 12 Transient protection for the VariStroke-I is to be provided externally by the end user. The transient protection device is to be set at a level not exceeding 140% of the peak rated voltage. The installation of the VariStroke-I shall only be within a Pollution Degree 2 environment as defined in IEC 60664-1.
  • Page 13 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator EXPLOSION HAZARD—Do not remove covers or connect/disconnect electrical circuits 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.

  • Page 14: Chapter 1. General Information

    VariStroke’s unique “variable stroke” capability also allows users to customize/set the actuator’s exact maximum stop position in the field to meet their requirement. The VariStroke-I is available as an integrated unit, or as a Remote Servo kit where the cylinder can be mounted up to 3 meters (approx.
  • Page 15 Designed for a continuous side load of up to 10% of actuator output, the VariStroke-I actuator incorporates a high-force precision bearing and triple-seal technology on its output shaft to solve this typical application problem.

  • Page 16: Vs-I Integrated And Remote Construction

    Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator VS-I Integrated and Remote Construction The VariStroke-I is made up of the following major components (Figure 1-1): Hydraulic Power Cylinder Rotary Servo Valve Feedback Sensors: MLDT (Magnetostrictive Linear Displacement Transducer) – for power cylinder...

  • Page 17: Figure 1-2. Varistroke-I Remote, Key Features

    Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator The VariStroke-I Remote Servo Kit (Figure 1-2) contains the same primary components as integrated version, this kit allows the Hydraulic Power Cylinder to be mounted separately from the servo in applications where space is constrained.

  • Page 18: Figure 1-3. Hydraulic Power Cylinder - Stroke Adjustment Options

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Hydraulic Power Cylinder The simple and robust design of VS-I hydraulic cylinder (Figure 1-3) is capable of consistent performance for extended periods in challenging environments. Hydraulic cylinder is designed to operate in wide range of hydraulic pressures and with high oil contamination.

  • Page 19: Figure 1-4. Application Example

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator If the unit detects any diagnostic shut down condition, or if the detected diagnostic condition prevents reliable control, or if a loss of power occurs, the servo valve return spring forces the valve to connect the appropriate control pressure to drain causing the cylinder to move to the fail-safe position.

  • Page 20: Vs-I Remote Servo Only Construction

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator The power supply system performs the EMI filtering on the (18 to 32) V (dc) input voltage, generates controlled voltages for several electronics sub-systems and is monitored for proper operation. If input voltage or internal power systems are detected outside of allowable operating ranges, a diagnostic alarm will be enunciated.

  • Page 21: Figure 1-5. Varistroke-I Remote Servo, Key Features

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 1-5. VariStroke-I Remote Servo, Key Features Hydraulic Power Cylinder The VariStroke Remote Servo can be connected to any hydraulic cylinder, however; proper operation requires that the VariStroke Performance Equation be satisfied (see Chapter 2, Performance Index). In order to control cylinder position, the Cylinder must be equipped with a position feedback sensor.

  • Page 22: Figure 1-6. Nomenclature And Ordering Number Encoder

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 1-6. Nomenclature and Ordering Number Encoder Note: Chemically resistant versions are denoted "CR" in the Specials string of the VariStroke model number. Please contact Woodward for available models. Woodward...

  • Page 23: Chapter 2. Specifications

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Chapter 2. Specifications Physical and Performance Specifications Table 2-1. Bore and Rod Diameter by Valve Size Bore Diameter (OD) Rod Diameter (ID) 4 inches (101.6 mm) 1.75 inches (44.5 mm) 5 inches (127.0 mm) 1.75 inches (44.5 mm)
  • Page 24 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator The formulas above are valid for double acting cylinders. For spring-assist actuators, additional spring force and its direction has to be taken in to account. Extending Slew Rate: Configurable Retracting Slew Rate: Configurable Note: Slew Rates for Remote Servo Applications may be 10–15% slower due to pressure drop on...
  • Page 25 It is for this reason that Woodward does NOT recommend using a combination of LVDTs and Signal Conditioners. This combination will typically result in unacceptable delays in the position sensor update rate.

  • Page 26: Figure 2-1. Vsi Maximum Transient Flow Rates (During Full Slew)

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Fluid Cleanliness Level: ISO 4406 code 20/18/16 or cleaner Output Cylinder Action: Double Hydraulic Connections Hydraulic Supply Port: 1.250 SAE Code 61 Flange Hydraulic Drain Port: 1.500 SAE Code 61 Flange Integrated Actuators: Hydraulic Connections Hydraulic Supply Port: 1.250 SAE Code 61 Flange...

  • Page 27: Special Ambient Temperature Specifications / Allowances

    V45 servo valve. Special Ambient Temperature Specifications / Allowances The following information applies only to a VariStroke-I installed in a non-hazardous (Ordinary) location. If the VariStroke-I is installed in to a Hazardous (Zones or Divisions) environment, the Special Ambient Temperature Allowances do NOT apply.

  • Page 28: Performance Index

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Performance Index The VariStroke product line is designed to bring a multitude of benefits to the actuation market place. One the primary benefits a customer will realize is the VariStroke’s ability to combine high-speed actuation with low-pressure hydraulic systems.

  • Page 29: Diagrams

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 2-3. Performance Chart for 4”, 5”, and 6” Bore Actuators Diagrams Functional Block Diagram Figure 2-4. Basic Device Block Diagram without Trip Function Woodward...

  • Page 30: Figure 2-5. Vs-I Integrated Hydraulic Schematic

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator VS-I Integrated Hydraulic Schematic Figure 2-5. VS-I Integrated Hydraulic Schematic VS-I Remote Servo Hydraulic Schematic Figure 2-6. VS-I Remote Hydraulic Schematic Woodward...

  • Page 31: Figure 2-7. Vs-I Remote Servo Hydraulic Schematic

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator VS-I Servo Only Hydraulic Schematic Figure 2-7. VS-I Remote Servo Hydraulic Schematic Figure 2-8. VS-I Spring Assist Integrated Hydraulic Schematic Woodward...

  • Page 32: Figure 2-9. Vs-I Spring Assist Remote Hydraulic Schematic

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 2-9. VS-I Spring Assist Remote Hydraulic Schematic Woodward...
  • Page 33 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Outline dimensions and installation features for specific models are in the appropriate appendix in the Appendices section (at the end of this manual) according to the below table. Table 2-8. VS-I Installation Drawings...
  • Page 34 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Notes These general reference outline drawings apply to Woodward VS-I only. Consult Woodward for the latest outline drawing. Installation Orientation: a. Cylinder - any orientation is acceptable. b. Servo valve - any orientation except upside down. Recommend vertical orientation.

  • Page 35: Chapter 3. Installation

    The VS-I is carefully packed at the factory to protect it from damage during shipping; however, careless handling during shipment can result in damage. If any damage to the VS-I is discovered, immediately notify both the shipping agent and Woodward. Unpacking Instructions Carefully unpack the VS-I and remove it from the shipping container.

  • Page 36: Installation Instructions

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Installation Instructions General See the outline drawings and Specifications for: Outline dimensions • Hydraulic connections and fitting sizes • Electrical connections • Weight of the VS-I • A vertical actuator position is generally preferred to conserve floor space as well as ease of making electrical and hydraulic connections.

  • Page 37: Figure 3-1B. Vs-I Integrated Product Installation Interface - Bolting Pattern And Installation Features

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 3-1b. VS-I Integrated Product Installation Interface - Bolting Pattern and Installation Features Woodward...

  • Page 38: Figure 3-2A. Vs-I Remote. Product Installation Interface - Bolting Pattern And Installation Features

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Installation Dimensions for Remote Servo Kit Figure 3-2a. VS-I Remote. Product Installation Interface - Bolting Pattern and Installation Features Woodward...

  • Page 39: Figure 3-2B. Vs-I Remote. Product Installation Interface-Bolting Pattern And Installation Features

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 3-2b. VS-I Remote. Product Installation Interface—Bolting Pattern and Installation Features Table 3-1. VS-I Installation Bolts and Bolting Torques Recommendation Thread “T1” & “T2” VariStroke Size Min Thread Min Bolt Bolting Torque Thread Tol.

  • Page 40: Figure 3-2C. Hydraulic Rod Position For Different Cylinders Versions

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 3-2c. Hydraulic Rod position for different cylinders versions Fail Extend, Spring Assist Cylinders with no hydraulics have cylinder rod in fully extended position. For all fail retract spring assist cylinders the hydraulic rod is in retract position without hydraulic pressure.

  • Page 41: Figure 3-3. Vs-I Remote Servo. Product Installation Interface - Bolting Pattern

    Figure 3-3. VS-I Remote Servo. Product Installation Interface - Bolting Pattern Minimum Bolt Grade, Bolting Torque and Thread Engagement Recommendation is valid for low carbon steel mounting surface to which product is bolted. For different configuration please consult Woodward for torque and bolts grade recommendations. Woodward...

  • Page 42: Figure 3-4. Vs-I Lifting Positions

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Lifting VariStroke comes equipped with lifting brackets for vertical lifting. When transporting, use both brackets as shown below. Remote Servo and Remote Cylinder have their own, separate lifting features. Transport both Integrated and Remote Servo units in either the vertical or the horizontal position.

  • Page 43: Figure 3-5. Incorrect Lifting Method

    For VS-I Integrated, the user is obligated to maintain the minimum required gap between servo valve and the actuator installation surface. For reference see outline drawing (Figure 3-1). Any mounting deviation from the one recommended by Woodward might cause assembly damage, improper performance or operator injury risk.
  • Page 44 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Ensure that the linkages and couplings connecting the VS-I output shaft to the turbine are appropriately sized and are able to withstand the stall force and dynamic loads. The lifting eye located on the top of the VS-I Servo Valve is intended to lift ONLY the servo itself, not integrated servo-cylinder configurations.

  • Page 45: Figure 3-6. Suggested Configuration

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator The hydraulic drain should be 38 mm (1.5 inches) tubing or larger and must not restrict the flow of fluid from the actuator. The drain pressure must not exceed 10% of supply pressure or 3.4 bar (50 psig), whichever is less, under any condition.
  • Page 46 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator For step demands and/or trip movements actuator may generate pressure spikes in supply line due to water hammer effect. Hydraulic accumulator in supply line installed close to the VariStroke can considerably reduce or eliminate this effect.

  • Page 47: Figure 3-7. Electrical Wiring Diagram

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Electrical Connections Figure 3-7 shows an overall electrical wiring diagram. Detailed wiring requirements for these connections will follow in the remainder of the Electrical Connections section. The RS-232 connection is covered in Chapter 4 (Installing and Running the PC Service Tool).

  • Page 48: Figure 3-8. Power Supply Input Connections

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Input Power The VS-I requires a power source capable of supplying the necessary output voltage and current at full transient conditions. The maximum power in watts (W) of a DC source is calculated by multiplying the rated output voltage by the maximum output current capability.

  • Page 49: Figure 3-9. Correct Wiring To Power Supply Input

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Although the VS-I is protected against input voltage transients, good wiring practices must be followed. The following drawings illustrate correct and incorrect wiring methods to the power supply. Figure 3-9. Correct Wiring to Power Supply Input Figure 3-10.

  • Page 50: Figure 3-11. Recommended Wiring Strain Relief

    Installations with severe electromagnetic interference (EMI) may require additional shielding • precautions. Contact Woodward for more information. Do not ground shield on both ends, except where permitted by the control-wiring diagram. •...

  • Page 51: Figure 3-12. Analog Input Connections

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Demand Analog Inputs There are two demand analog inputs to the VS-I. Demand Input #1 is dedicated to the demand input. For application where reliability is critical, the Demand Input #2 can be configured for a redundant demand input.

  • Page 52: Figure 3-13. Final Cylinder Position Feedback Analog Input Connections

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Cylinder Position Feedback Analog Inputs (Remote Servo Only) There are two Final Cylinder Position Feedback analog inputs. Refer to the service tool chapter for information on configuring these inputs. VS-I Cylinder Position Feedback...

  • Page 53: Figure 3-15. Cylinder Position Sensor Wiring Diagram When Using External Power Supply

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 3-15. Cylinder Position Sensor Wiring Diagram When Using External Power Supply Figure 3-16. Example of Incorrect Cylinder Position Sensor Connection When Using External Power Supply When using external power supply, do NOT connect it to VS-I driver power outputs on the Position Feedback terminals.

  • Page 54: Figure 3-19. Analog Output Connection

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Cylinder Position Feedback Analog Input Wiring Requirements: Individually shielded twisted pair cable • Keep this and all other low level signal cables separated from input power cables to avoid • unnecessary coupling (noise) between them.

  • Page 55: Figure 3-20. Discrete Inputs Connections

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Discrete Inputs The VS-I has four discrete inputs. External power is not necessary for these inputs as the isolation is provided internally. The discrete inputs have an internal pull-up resistor and are inverted at the processor, such that an open circuit is the passive low state.

  • Page 56: Figure 3-21. Discrete Output Connections

    Refer to the service tool chapter for configuration information. Wire the outputs to switch load from positive supply or switch load to ground. Woodward recommends that the output be used as a high side driver as shown in the diagram below. This configuration makes some common wiring faults to ground more detectable in the user system.

  • Page 57: Figure 3-22. Can Ports Connections

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Response Time: Less than 2 ms On-state Saturation Voltage: Less than 1 V @ 500 mA Off-state Leakage Current: Less than 10 μA @ 32 V Isolation: 500 V (ac) from digital ground and chassis...
  • Page 58 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator CAN Cable Shield Termination & Exposed Cable Limitations For robust communications performance, the CAN cabling needs to minimize the exposed, non-shielded cable section that occurs at terminal blocks. The exposed length of CAN wiring must be limited to less than 3.8 cm (1.5 inches) from the end of the shield to the terminal block.

  • Page 59: Chapter 4. Service Tool Installation

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Chapter 4. Service Tool Installation System Requirements The minimum system requirements for the Service Tool software are: Microsoft Windows® 7, Vista SP1 or later, XP SP3 (32 & 64-bit); Support of XP ended on 2014 April 8 •...

  • Page 60: Installing The Varistroke-I Service Tool

    Installing the VariStroke-I Service Tool Use the following installation procedure to install the VariStroke-I Service Tool (Programming and Configuration Tool). Locate/obtain VS-I Service Tool Installation CD provided with each VS-I. (Alternatively, you may download the VS-I Service Tool Installation file from Woodward’s website...

  • Page 61: Figure 4-2. Service Tool Welcome Screen

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator To run the installation program follow the installation instructions (shown below). Double click on the install file 9927-2177_xxx.exe. Note: xxx is a placeholder for the revision of the install package i.e. 9927-2177_NEW.exe. or 9927- 2177_A.exe are examples of Rev NEW and Rev A versions.

  • Page 62: Figure 4-4. Service Tool Installation Screen

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator The Install page appears. “Create shortcut for this program on the desktop” is set as the default. Uncheck this box if you do not want a Service Tool icon on your desktop. Click on “Install”.

  • Page 63: Figure 4-6. Installation Complete And Finish Screen

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator If you launch the service tool application before you connect the serial cable between the computer and the VS-I the service tool will not detect the new serial connection. To detect the connection you will have to exit and re-launch the service tool.

  • Page 64: Connecting To The Varistroke-I

    VariStroke-I (VS-I) Electro-hydraulic Actuator Connecting to the VariStroke-I To connect to the VariStroke-I (VS-I) connect a serial cable between the computer and the VS-I driver then double-click on the service tool icon on the desktop. The service tool will launch and the next screen you will see will be the Home Screen of the VS-I service Tool.

  • Page 65: Chapter 5. Calibration And Monitoring

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Chapter 5. Calibration and Monitoring Introduction The VS-I Service Tool is organized in to a series of pages that allow the VS-I to be set up for proper operation. The following section will outline the various pages and their functions.
  • Page 66 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Shutdown LED: When this LED indicator is illuminated, this invokes a shutdown condition. The unit receives a command to shut down or has detected an operating condition, which adversely affects the unit’s ability to operate reliably and predictably. Refer to Chapter 7 for a list of shutdown conditions.

  • Page 67: System Information Page

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator System Information Page This page will display system information about the VS-I servo that is currently connected to the PC Service Tool. Figure 5-2. System Information Page Actuator P/N, S/N, Revision: These fields display the Actuator Assembly Part Number (P/N), Serial Number (S/N), and Revision Number.

  • Page 68: Configuration And Calibration

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Configuration and Calibration To prevent personal injury or death and damage to equipment, the controlled prime mover must not be allowed to run or operate during any of the following procedures. The main steam valve or main fuel control must be turned off to prevent operation of the controlled system.

  • Page 69: Cylinder Configuration

    Position Sensor Length be slightly longer than the Cylinder Length in order to ensure the sensor output is always within the usable (4–20 mA) range. For a list of standard / Woodward position sensor lengths used in Integrated and Remote Servo Kits, refer to the table shown in Chapter 7: Repair and Troubleshooting.
  • Page 70 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Failure to input the correct Supply Pressure can result in unstable actuator performance. Ensure that this setting is correct and that the system pressure regulators do not allow more than a ±10% variation in Supply Pressure.

  • Page 71: Figure 5-4. Service Tool Calibration Screen

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator The Calibration features will cause the actuator to move. Ensure all personnel are clear of moving components before initiating the calibration sequence. Potential damage to linkage and/or attachments can occur if the linkage and/or attachments are not designed to withstand the full stall force of the actuator at the supplied operating pressure.

  • Page 72: Figure 5-5. Calibration Find Minimum Stop Screen

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator To use the Find Minimum Stop option, press the “Find Minimum Stop” button. The Find Minimum Stop feature allows the user to scale the desired minimum position offset and maximum stop position to the 4 to 20 mA demand input range.

  • Page 73: Figure 5-6. Calibration In Progress Screen

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Immediately after this, the VS-I servo valve will slightly open in the opposite direction to slowly move the actuator toward the maximum position. The actuator will move a small distance off the minimum stop, pause for a brief moment to determine an acceptable slew rate, and then continue to move toward the maximum position.

  • Page 74: Figure 5-7. Calibration Complete Screen

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Set Offset and Maximum Stop Position If one of the calibration routines has already been run, or the user wishes to adjust these values based on the factory calibration, the “Adjust Minimum Offset and Maximum Position” button may be pressed.

  • Page 75: Manual Operation

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Saving the Calibration Settings To save the new “Offset at Minimum Position” and “Maximum Stop Position” settings, press the “Save Calibration” button. Press the “Cancel/Revert Calibration” button to discard the changed values and to exit the calibration.

  • Page 76: Chapter 6. Configuration

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Chapter 6. Configuration Input Configuration Figure 6-1. Input Configuration Screen The analog input settings including scaling and diagnostics levels are displayed from this screen. The values of the current operational and diagnostic settings are also displayed.
  • Page 77 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Demand Inputs Demand Input 1 / 2: Displays the value (in percent position) of the individual demand signals. Demand: Displays the value (in percent position) of the demand signals after they have been averaged, low signal selected, or high signal selected.

  • Page 78: Output Configuration

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Reset The VariStroke has a dedicated, discrete input for resetting the driver. The actuator will clear all alarms and shut downs when this circuit is closed. The actuator will then resume operation as long as valid demand signals are present and there are no active shut downs.
  • Page 79 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Mode: Configures the discrete output mode to one of the following options. Unused/Manual: Sets the discrete output to unused. This mode can also be used to manually toggle • the output by switching the “Energize Results” In configuration.

  • Page 80: Advanced Configuration

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Advanced Configuration Advanced Configuration Page Figure 6-3. Advanced Configuration Screen Bandwidth: Adjusts how fast the actuator will respond to a demand input change. The higher the setting adjusted, the faster the actuator will respond, but the more sensitive it will be to electrical noise on the demand signal.

  • Page 81: Linearization

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Linearization This table is used to linearize steam flow to actuator position. It can only be modified when the actuator is shut down. Figure 6-4. Linearization Screen Enabled / Disabled: Enables or Disables the demand curve (linearization) functionality.

  • Page 82: Figure 6-5. Alarms And Shutdowns Screen

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 6-5. Alarms and Shutdowns Screen Diagnostic Values: Supply Voltage: Indicates the supply voltage value. Internal Actuator Drive Current: Indicates the actuator drive current. Woodward...

  • Page 83: Figure 6-6. Alarms And Shutdowns Configuration Screen

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Configure Alarms/Shutdowns Page Figure 6-6. Alarms and Shutdowns Configuration Screen From the Alarm/Shutdown Configuration page, some of the alarms and shut downs can be configured. Editable faults are shown as colored buttons on the page. The colored buttons can be configured based...

  • Page 84: Saving And Loading Settings

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Saving and Loading Settings It is highly recommended that the user save the VS-I settings after calibration and configuration. Save these settings for the user’s future reference. These settings can also be loaded in to another VS-I should the unit ever be replaced.

  • Page 85: Chapter 7. Repair And Troubleshooting

    36 months from the date of shipment from Woodward. It is recommended that all repairs and servicing of the VS-I be performed by Woodward or its authorized service facilities.

  • Page 86: Figure 7-1. Shaft Seals Replacement Kits And Installation

    Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Figure 7-1. Shaft Seals Replacement Kits and Installation Woodward...

  • Page 87: Servo Valve / Hydraulic Cylinder Replacement

    Before performing any repairs or replacement procedures to the VS-I, all Product Support Options listed in Chapter 8 should be understood and considered. If it is determined that a Servo Valve or Hydraulic Cylinder must be replaced, replacement procedures can be found in Woodward manual 26836, VariStroke-I Replacement Procedures. Troubleshooting General The following troubleshooting guide will help you isolate trouble with the servo valve, hydraulic power cylinder, control circuit board, wiring, and system problems.
  • Page 88 Released Manual 26727 VariStroke-I (VS-I) Electro-hydraulic Actuator Ensure the Used / Not Used settings inside the VS-I match the Active/Inactive settings of the controller. Settings can be modified using Run Enable configuration problem. the Service Tool. If the Run Enable is not used, disable this function using the Service Tool.

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