Woodward VariStroke-DX Component Maintenance Manual
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Woodward VariStroke-DX Component Maintenance Manual

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Released
CMM-03013
REV.-
09-22
Component Maintenance Manual
Bronze Level
Product Name: VariStroke-DX (VS-DX)
FOR GENERAL DISTRIBUTION
1

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  • Page 1 Released CMM-03013 REV.- 09-22 Component Maintenance Manual Bronze Level Product Name: VariStroke-DX (VS-DX) FOR GENERAL DISTRIBUTION...

  • Page 2: Table Of Contents

    Electrostatic Discharge Awareness ....................................12 Definitions and Used Abbreviations ....................................12 List of Woodward Literature ......................................13 List of Woodward Required Software ..................................... 14 List of Required Hardware or Materials ..................................14 General Instructions ........................................16 ON-LINE SERVO VALVE REPLACEMENT, VS-DX SKID J-BOX VERSION ........................17 Replacement Kit Description ......................................
  • Page 3 Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 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.
  • Page 4 Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 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.
  • Page 5 Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 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.
  • Page 6 26455 check manual , Customer Publication Cross Reference and Revision Status & Distribution Restrictions, on the publications page of the Woodward website: www.woodward.com Revisions 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.

  • Page 7: 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.
  • Page 8 Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 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...
  • Page 9 Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 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...

  • Page 10: Warnings And Notices

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 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.
  • Page 11 Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 Before performing maintenance, always disconnect power and any hazardous voltages that may be connected. Follow all appropriate lockout-tagout procedures. Disconnect Power Supply 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.

  • Page 12: Electrostatic Discharge Awareness

    To prevent damage to electronic components caused by improper handling, read and observe the precautions in 82715 Woodward manual , Guide for Handling and Protection of Electronic Controls, Printed Circuit Boards, and Modules. Follow these precautions when working with or near the control: Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic materials.

  • Page 13: List Of Woodward Literature

    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.

  • Page 14: 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.
  • Page 15 • 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 Others • Isopropyl alcohol • Petroleum jelly •...

  • Page 16: General Instructions

    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.

  • Page 17: On-Line Servo Valve Replacement, Vs-Dx Skid J-Box Version

    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.
  • Page 18 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.
  • Page 19 Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 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. Overspeed / The overspeed shutdown device must be completely independent of the prime mover Overtemperature /...

  • Page 20: Varistroke Servo Disassembly Procedure From Vs-Dx Skid

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 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.

  • Page 21: Figure 2-2. Vs-Dx Isolation Valves Position

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 2. Confirm that the other servo is designated VariStroke A Servo is Isolated VariStroke B Servo is Isolated as the Master. a) Control system commands the other servo to be designated as the Master [notate result in Checklist: ID #4].

  • Page 22: Figure 2-3. Vs-Dx J-Box Opening

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 7. If the RunEnable command is used, set the command to False in the control system for the VariStroke to be disassembled [notate result in Checklist: ID #9]. a) The feedback signal in the control system will indicate that the VariStroke to be disassembled is in a Shutdown state.

  • Page 23: Figure 2-6. Set Screw In Varistroke Cover

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 10. Verify the withdrawn VariStroke memory or parameter fault [notate result in Checklist: ID #12]. 19. Download and save parameters from the withdrawn VariStroke. Refer to Customer Service Tool communicates the alarm in the control manual 35148.

  • Page 24: Figure 2-9. Disconnecting Rs-232 Link

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 23. Alarm will appear in the control system of the other controlling VariStroke. Best practice is to save files settings from each VariStroke in the plant. Files should be saved and stored after each successful/finalized configuration change or calibration performed.

  • Page 25: Figure 2-11. Health Link Terminals Inside Vs-Dx J-Box

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 24. Cut-off the hydraulic supply to the withdrawn VariStroke (valve is located on system process piping – not provided with VS-DX) [notate result in Checklist: ID #16]. 25. Wait for two minutes. 26. Cut-off the hydraulic drain to the withdrawn VariStroke (valve is located on the system process piping –...
  • Page 26 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,...

  • Page 27: Figure 2-13. Cable Ties Removal Inside Varistroke

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 30. Close the front cover of the junction box. 31. Verify all wire ends and terminals are properly marked in the VariStroke connection compartment. If not, mark according to the wiring diagram (see manual 35132).

  • Page 28: Figure 2-15. Signals Connector Placement Inside Varistroke

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 34. Unscrew cables from VariStroke terminals #1 to 22 (use slotted screwdriver; 2.5 X 0.4 mm tip size) (Figure 2-15). 35. Unscrew grounding (use Phillips screwdriver; PH2 tip size) (Figure 2-16). Figure 2-15. Signals Connector Placement Inside VariStroke Figure 2-16.

  • Page 29: Figure 2-17. Varistroke Wires Protected With Vinyl Electrical Tape

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 36. Unscrew 7 screws from the VariStroke PCB cover (use Phillips screwdriver; PH2 tip size) (Figure 2-18). 37. Pick up the VariStroke PCB cover carefully as to not damage cables or PCB. 38. Verify all wire ends and terminals are properly marked on sensor wires.

  • Page 30: Figure 2-20. Varistroke J-Box Conduit Nut Loosening

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 41. Loosen the conduit nut on the junction box side (use 1 1/2 in open end wrench). Counter the junction box fitting (use 1 13/16 in open end wrench) (Figure 2-20). 42. Unscrew the conduit nut on the servo side (use 1 1/2 in open end wrench) (Figure 2- 21).

  • Page 31: Figure 2-23. Varistroke Conduit Rotation

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 44. Feed the cable through the conduit toward the junction box, allowing the conduit to be rotated (Figure 2-23). VariStroke “A” 45. Carefully pull each bundle of wires side view individually by the VariStroke port to VariStroke “B”...

  • Page 32: Figure 2-25. Pcb Holding Screws Placement Inside Varistroke

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 46. Install the VariStroke PCB cover with 7 screws (use Phillips screwdriver; PH2 tip size). Note: There are two different lengths of screw (L=long, S=short); (Figure 2-25). 47. Install the VariStroke cover and torque to 100 ±10 LBFT (135 ±13.5 Nm) using a 2 1/4 in open end wrench (Figure 2-26).

  • Page 33: Figure 2-27. Varistroke Cover Set Screw Installation

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 Failure to install the set screw could compromise the method of protection. 48. Screw in set screw in the withdrawn VariStroke cover (use 1.5 mm socket head wrench). Thread the set screw into the cover until the end of the screw is flush with the top surface of the cover (Figure 2-27).
  • Page 34 Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 50. Place the oil collection container/oil absorbent mats under the piping being disconnected. Potential for residual hot oil spillage exists. It is recommended to place oil absorbent pads or a container underneath the servo assembly (5 liter capacity minimum) to collect residual oil leakage.

  • Page 35: Figure 2-29. Varistroke With Lifting Strap Installed

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 Remember to support the servo while Lifting strap disassembling. Ensure the crane, cables, straps, and all other lifting equipment, as well as the lifting lug being used for servo-valve transportation, can support the servo- valve weight.

  • Page 36: Figure 2-31. Varistroke Disconnection

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 56. After unscrewing all four bolts, use lifting equipment to gently support the disjointed Alignment Pins servo by pushing/pulling it in the directions shown in Figure 2-31. 57. Transport the withdrawn VariStroke away from the VS-DX skid manifold.

  • Page 37: Varistroke Servo Installation Procedure On Vs-Dx Skid

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 VariStroke Servo Installation Procedure on VS- Note: Lower port seal not DX Skid required 1. Remove the shipping plate by unscrewing all four bolts (use 3/4 in open end wrench) (Figure 2-34). 2. Clean connection interface surfaces using Isopropanol alcohol (Figure 2-35).

  • Page 38: Figure 2-36. Eyebolt Installation

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 4. Unscrew the bolt from the new VariStroke cover (use 3/4 in open end wrench) and counter cover (use 2 1/4 in open end wrench) (Figure 2-36). 5. Screw the .500-13 thread eyebolt to the VariStroke cover (if it had been removed and used earlier while removing the servo from the skid).

  • Page 39: Figure 2-38. Varistroke Alignment With Vs-Dx Manifold

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 7. Align the new VariStroke servo with the VS- DX manifold using two dowel pins (Figure 2-38). Ensure sealing O-rings are correctly placed in their grooves during servo connection process. 8. Connect the servo with the VS-DX manifold. (Figure 2-39).

  • Page 40: Figure 2-40. Varistroke Four Mounting Screws (Vs-Dx Section View)

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 9. Finalize the servo connection by tightening the four bolts (use 3/4 in open end wrench, tighten to 50 ± 5 LBFT (68±7 Nm) (Figure 2-40). 10. Release and remove the lifting strap used to secure the VariStroke servo during assembly.

  • Page 41: Figure 2-44. Varistroke Cover Opening

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 14. Open the new VariStroke cover (use 2 1/4 Clean conduit adapter in open end wrench) (Figure 2-44). thread on this side Figure 2-45. Cleaning Conduit Adapter Thread Figure 2-44. VariStroke Cover Opening 15.

  • Page 42: Figure 2-47. Varistroke Conduit Adapter Installation

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 18. Apply Loctite 592 to the previously cleaned Apply Loctite 592 to the tapered threads prior to assembly. Install the conduit adapter tapered adapter into the servo’s “power” port hole. thread before screwing Tighten installed fitting on the servo side to into VS power port.
  • Page 43 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,...

  • Page 44: Figure 2-49. Vinyl Electrical Tape Protection Removed From Wires

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 22. Remove the protective electrical tape after placing the cable inside the VariStroke PCB compartment (Figure 2-49). 23. Unscrew seven screws from the VariStroke PCB cover (use Phillips screwdriver; PH2 tip size) and remove the cover. Note: There are two different lengths of screw (L=long, S=short) (Figure 2-50).

  • Page 45: Figure 2-51. Actuator Position Sensors Terminals Placement Inside Varistroke

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 24. Connect position sensor(s) cables to the orange terminal [SENS 1 -PWR; SENS 1 -SIG; SENS 1 +SIG; SENS 1 +PWR; SENS 2 -PWR; SENS 2 -SIG; SENS 2 +SIG; SENS 2 +PWR]. Torque to 6.2 ±0.9 LBIN (0.7 ±0.1 Nm) (use Philips screwdriver;...

  • Page 46: Figure 2-53. Vs-Dx J-Box Opening

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 27. Install signal cables to VariStroke terminals #1 to 22. Torque to 6.2 ±0.9 LBIN (0.7 ±0.1 Nm) (use slotted screwdriver; 3.5 X 0.6 mm tip size) (Figure 2-54). HINT: To avoid connection error between cable numbers #6 and #9, verify cable color: Terminal #6: connected cable color: WHITE Terminal #9: connected cable color:...

  • Page 47: Figure 2-56. Discrete Outputs And Analog Outputs, Terminals Inside Vs-Dx J-Box

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 31. Close the knife disconnect terminals for the newly installed VariStroke [Discrete Outputs] (VariStroke A terminals #23 through 26, 4 terminals) (VariStroke B terminals #54 through 57, 4 terminals) (Figure 2-56 and Figure 2-57). 32.

  • Page 48: Figure 2-59. Power Terminals Inside Vs-Dx J-Box

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 34. Reinstate the electrical power to the new VS-GI unit “A” PWR Terminals VariStroke: a) Close knife terminals in the [POWER] junction box : VariStroke A terminals #2 through 5, 4 terminals) (VariStroke B terminals #33 through 36, 4 terminals) (Figure 2-59) b) Power on the supply circuit at the...

  • Page 49: Figure 2-61. Vs-I Customer Service Tool Home Screen

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 36. Launch the VariStroke Customer Service Tool application. 37. Establish a connection to the newly installed VariStroke by pressing the connect button in the Customer Service Tool software. (Figure 2-61). 38. Load the VariStroke settings file from a PC to the new VS-GI (Figure 2-62).

  • Page 50: Figure 2-63. Cylinder Tracking Alarm/Shutdown Configuration

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 39. Save configuration values (Figure 2-64) 40. On the Configure Alarms/Shutdowns Customer Service Tool Save Values screen, verify that Cylinder Tracking button Alarm has configuration “E A N” (Enable/Alarm/Non-Latched) and Cylinder Tracking Fault has configuration “E A L” (Enable/Alarm/Latched) (Figure 2-65).

  • Page 51: Figure 2-66. Alarms/Shutdowns Page

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 41. Reset alarms by using the Reset button on Alarms/Shutdowns screen (Figure 2-66). Customer Service Tool Reset Alarms/Shutdowns button Figure 2-66. Alarms/Shutdowns Page...

  • Page 52: Figure 2-67. Redundancy Screen - Air Bleeding Control Screen

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 42. Open the hydraulic drain to the new Air Bleeding page is available only for redundant servo VariStroke (valve located on system configuration VS-DX. process piping – not provided with VS-DX) [notate result in Checklist: ID #1]. 43.

  • Page 53: Figure 2-69. Servo Air Bleeding Completed

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 The servo air bleeding procedure takes about 20-30 minutes depending on the supply oil pressure. Please be patient. The Customer Service Tool will confirm when the procedure has ended. 46. Confirm the “Servo Air Bleeding Procedure is Completed”...

  • Page 54: Figure 2-70. Run Enable And Reset Status On The Input Configuration Screen

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 c) From the control system, command the Reset value to False. d) In the Customer Service Tool, verify the current Reset status is Circuit Open (Figure 2-70) [notate result in Checklist: ID #16]. Review the Customer Service Tool software pages and verify that the parameterization/settings are aligned with...

  • Page 55: Figure 2-71. Analog Demand Terminals

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 50. In the control system, verify that the new VS-GI unit “A” analog DMD terminals VariStroke communicates Shutdown active [notate result in Checklist: ID #23]. 51. Close knife terminals [ANALOG DMD CH1, for the new VariStroke ANALOG DMD CH2] (Figure 2-71) (VariStroke A terminals # 17 through 22,...

  • Page 56: Figure 2-73. Redundant Feedback Pulse Error On The Alarms/Shutdowns Screen

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 53. In the control system, verify that the new VariStroke does not communicate Shutdown [notate result in Checklist: ID #24]. 54. In the control system, verify that the new VariStroke communicates Alarm active [notate result in Checklist: ID #21].

  • Page 57: Figure 2-75. Redundancy Screen And Alarm/Shutdown Annunciation

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 57. On the Alarm/Shutdown screen, verify that Redundant Feedback Pulse Error is not currently active in the Alarm column [notate result in Checklist: ID #20] (Figure 2-73). Redundancy screen 58. In the control system, verify that the new VariStroke does not communicate Alarm.

  • Page 58: Figure 2-76. Discrete Outputs Terminals Inside Vs-Dx J-Box

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 61. Close knife disconnect terminals for the newly installed VariStroke [Discrete Output] (VariStroke A terminals #27, 28) or (VariStroke B terminals #58, 59) (Figure 2-76). 62. In the control system, verify that the new VariStroke still communicates as NotInControl [notate result in paper Checklist: ID #26].

  • Page 59: Figure 2-78. Alarms And Shutdowns Screen

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 66. Using the Customer Service Tool software, Alarms and Shutdowns navigate to the Alarms/Shutdowns screen screen and click the Reset button to reset Shutdowns/Alarms on the newly installed VariStroke (Figure 2-78). Alarms and Shutdowns 67.

  • Page 60: Figure 2-79. Feedback Readings On The Input Configuration Screen

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 69. Perform verification and comparison of Position Feedback values between the control system and the newly installed VariStroke (Figure 2-79). These values must be identical, but very minor differences are expected. Register two readings to confirm the values are alive [notate result in Checklist: ID #7 and #8].

  • Page 61: Figure 2-81. Vs-Dx J-Box Closing

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 71. Close the front cover of the junction box (use a slotted screwdriver: 22.0 – 27.0 LBIN (2.5 – 3.0 Nm); 5.5 X 0.8 mm tip size) Screws (Figure 2-81). 72. Disconnect the RS-232 communication cable from the newly installed VariStroke.

  • Page 62: Figure 2-84. Varistroke Cover Installation

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 75. Assemble the newly installed VariStroke cover (use 2 1/4 in open end wrench: 90.0 – 110.0 LBFT (122 – 149 Nm) (Figure 2- 84). 76. Screw the set screw in the newly installed VariStroke cover (use 1.5 mm socket head wrench).
  • Page 63 Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 Recalibrate cylinder at the next turbine overhaul. At the next possibility, use the Customer Service Tool software to review the alarm logs on the VariStroke that was not replaced. 79. Install the padlock on the VS-DX isolation valve (if required). 80.

  • Page 64: Appendix 1. Dissasembly Checklist

    Released Appendix 1. Dissasembly Checklist CMM-03013, ON-LINE SERVO VALVE REPLACEMENT, VS-DX SKID J-BOX VERSION - DISASSEMBLY CHECKLIST Page 1 of 1 Date: Plant Name: Unit Plant ID / Functional location: Please do not proceed with actions in sequence of this checklist. VariStroke Part Number: VariStroke Serial Number: Proper order of actions is provided by the CMM-03013 procedure.

  • Page 65: Appendix 2. Assembly Checklist

    Released Appendix 2. Assembly Checklist CMM-03013, ON-LINE SERVO VALVE REPLACEMENT, VS-DX SKID J-BOX VERSION - INSTALLATION CHECKLIST Page 1 of 2 Date: Plant Name: Unit Plant ID / Functional location: Please do not proceed with actions in sequence of this checklist. VariStroke Part Number: VariStroke Serial Number: Proper order of actions is provided by the CMM-03013 procedure.
  • Page 66 Released CMM-03013, ON-LINE SERVO VALVE REPLACEMENT, VS-DX SKID J-BOX VERSION - INSTALLATION CHECKLIST Page 2 of 2 Date: Plant Name: Unit Plant ID / Functional location: Please do not proceed with actions in sequence of this checklist. VariStroke Part Number: VariStroke Serial Number: Proper order of actions is provided by the CMM-03013 procedure.

  • Page 67: Isolation Valve Replacement

    VS-DX SKID - 8935-1338 - KIT- REPLACEMENT ISOLATION VALVE, RIGHT HAND VS-DX SKID - 8935-1339 - KIT- REPLACEMENT ISOLATION VALVE, LEFT HAND, Follow this procedure during replacement. Please contact Woodward with any questions. List of Required Hardware or Materials Installation required torques ranges, wrench end type, and size •...

  • Page 68: Isolation Valve Removal

    WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 Isolation Valve Removal 1. Identify the control isolation valve to be replaced. The entire VariStroke-DX skid must be offline during isolation valve replacement. 2. Place the oil absorbent mat under VS-DX isolation valve to be replaced.

  • Page 69: Figure 3-3. Isolation Valve Bracket Retaining Screw Location

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 4. Loosen and remove the retaining screw on the handle of the lock bracket using a 3/16 in hex key wrench (Figure 3-3). Retaining screw. 5. Adjust the handle locking bracket position to Right hand reach all six screws retaining the isolation valve shown.

  • Page 70: Figure 3-5. Isolation Valve Removal

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 6. Loosen and remove all six screws using ½ in hex key wrench (Figure 3-5). 7. Remove isolation valve (Figure 3-5). Potential for residual hot oil spillage exists. It is recommended to place oil absorbent pads or a container underneath the servo assembly (5 liter capacity minimum) to collect the residual oil...

  • Page 71: Isolation Valve Installation

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 Isolation Valve Installation 1. Obtain replacement isolation valve kit 8935- 1338 (left hand) or 8935-1339 (right hand) containing isolation valve and soft sealing. Locking screw 2. Loosen and remove the screw locking handle lock bracket using 3/16 in hex key wrench (Figure 3-6).

  • Page 72: Figure 3-8. Isolation Valve Mating Surfaces Cleaning

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 4. Clean connection interface surfaces using Clean mating surfaces Isopropyl alcohol (Figure 3-8). 5. Lubricate O-rings (3 pieces) provided in the isolation valve kit with Parker Super O-Lube or petroleum jelly and install them in the valve seal grooves (Figure 3-9).

  • Page 73: Figure 3-10. Isolation Valve Mating Surfaces Cleaning

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 6. Apply anti-seize to the six screws and install them inside the isolation valve manifold (Figure 3-10). 7. Align isolation valve screws with VS-DX manifold threaded holes. Hand-tighten screws using a cross screwing pattern (Figure 3-10).

  • Page 74: Figure 3-12. Varistroke Isolation Valves In Horizontal Position

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 9. Adjust the valve locking bracket. Set valve crank in the horizontal position (Figure 3- 12). 10. Apply Loctite 242 to the locking screw and tighten using 3/16 hex key wrench. Installation torque: 89-99 LBIN (10-11 Nm) (Figure 3-13).

  • Page 75: Shuttle Valve Replacement

    The purpose of this procedure is to show the correct sequence and method of shuttle valve replacement: VS-DX SKID - 8935-1336- KIT- REPLACEMENT SHUTTLE VALVE Follow this procedure during replacement. Please contact Woodward with any questions. List Of Required Hardware or Materials...

  • Page 76: Shuttle Valve Removal

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 Shuttle Valve Removal 1. Shut-off both isolation valves by turning the cranks to the vertical position (Figure 4-1). 2. Place the oil collection container and absorbing mats under the piping being disconnected. Potential for residual hot oil spillage exists.

  • Page 77: Figure 4-3. Varistroke Shuttle Valve Retaining Screws

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 4. Loosen and remove all four screws retaining the shuttle valve using 3/8 in hex Shuttle Valve head wrench (Figure 4-3). mounting screws 5. Carefully pull-out the shuttle valve (Figure 4-4). Figure 4-3. VariStroke Shuttle Valve Retaining Screws Disconnect Figure 4-4.

  • Page 78: Figure 4-5. Shuttle Valve Locating Pin

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 6. Verify the locating pin is present in the shuttle valve (Figure 4-5). If not, remove it from the VS-DX manifold (Figure 4-6). Locating pin Figure 4-5. Shuttle Valve Locating Pin Remove Locating pin Figure 4-6.

  • Page 79: Shuttle Valve Installation

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 Shuttle Valve Installation 1. Obtain a new shuttle valve kit 8935-1336 Clean groove surfaces containing soft components and dowel pin installed. 2. Clean both mating surfaces of VS-DX manifold and shuttle valve manifold using Isopropyl alcohol (Figure 4-7).

  • Page 80: Figure 4-8. Shuttle Valve Installation Screws

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 3. Lubricate O-rings with Parker Super O-Lube or petroleum jelly and install into the ID groove of the shuttle valve manifold (Figure 4-9). 4. Align the shuttle valve with the VS-DX manifold using a dowel pin and connect. (Figure 4-10).

  • Page 81: Pressure Gauge Replacement

    The purpose of this procedure is to show the correct sequence and method of shuttle valve replacement: VS-DX SKID - 8935-1344- KIT- PRESSURE GAUGE Follow this procedure during replacement. Please contact Woodward with any questions. • Type: flat wrench; Size 19 mm •...

  • Page 82: Pressure Gauge Removal

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 Pressure Gauge Removal Needle valve lock 1. Loosen the needle valve adjuster locking nut using 13/16 in wrench. Using 3/16 in hex key, close the needle Pressure gauge valve located on top of housing, turning needle valve clockwise.

  • Page 83: Pressure Gauge Installation

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 Pressure Gauge Installation 1. Obtain a new pressure gauge Kit 8935- 1344. 2. Examine all mating surfaces for debris and dirt. If present, clean it before proceeding. Make sure sealing O-rings are correctly placed in their grooves during gauge installation process.

  • Page 84: Revision History

    Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 6. REVISION HISTORY REVISION REVISION DESCRIPTION PAGE # DATE LETTER OF CHANGE SEP 2022 Initial revision...
  • Page 85 Released WOODWARD___________________________________ COMPONENT MAINTENANCE MANUAL _____________________________________ CMM-03013 PO Box 1519, Fort Collins CO 80522-1519, USA 1041 Woodward Way, Fort Collins CO 80524, USA Phone +1 (970) 482-5811 Email and Website—www.woodward.com Woodward has company-owned plants, subsidiaries, and branches, as well as authorized distributors and other authorized service and sales facilities throughout the world.

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