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Woodward GS Series Installation And Operation Manual
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Woodward GS Series Installation And Operation Manual

Woodward GS Series Installation And Operation Manual

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Released
Product Manual 35136
(Revision L, 2/2025)
Original Instructions
GS Series
Installation and Operation Manual

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Summary of Contents for Woodward GS Series

  • Page 1 Released Product Manual 35136 (Revision L, 2/2025) Original Instructions GS Series Installation and Operation Manual...
  • Page 2 Always compare with the original for technical specifications and for proper and safe installation and operation procedures. If your publication is not on the Woodward website, please contact your customer service representative to get the latest copy. Revisions— A bold, black line alongside the text identifies changes in this publication since the last revision.
  • Page 3 Released Manual 35136 GS Series Contents ......................6 ARNINGS AND OTICES Electrostatic Discharge Awareness ......................7 Tampering Notice ............................7 ......................8 EGULATORY OMPLIANCE 1. G ................... 12 HAPTER ENERAL NFORMATION 2. T ..................13 HAPTER ECHNICAL PECIFICATIONS 3. I ......................
  • Page 4 Product Support Options ........................... 135 Product Service Options ........................... 135 Returning Equipment for Repair ....................... 136 Replacement Parts ............................ 137 Engineering Services ..........................137 Contacting Woodward’s Support Organization ..................137 Technical Assistance ..........................138 10. L ..............139 HAPTER TORAGE EQUIREMENTS A.
  • Page 5 Figure 3-5. Piping Requirements ........................ 32 Figure 3-6. GS Series Driver - Conduit Version ..................34 Figure 3-7a. GS Series Conduit Version System Wiring Diagram – Power Input ........36 Figure 3-7b. GS Series Conduit Version System Wiring Diagram – IO ............37 Figure 3-7c.
  • Page 6 Figure A-8. Frame Time Definition Block Diagram ................... 148 Table 3-1. 2-Inch & 1.5-Inch ANSI Flange Valves ..................30 Table 3-2. GS Series Valve Electrical Connections..................35 Table 3-3. GS Series Input Power Requirements ..................41 Table 3-4. Supply Voltage and Earth Ground ..................... 42 Table 3-5.
  • Page 7 Released Manual 35136 GS Series Table 3-39. Input Power Connector Pinout ....................70 Table 3-40. Power Cable Wire Colors ......................70 Table 3-41. Voltage Drop Using American Wire Gauge (AWG) ..............71 Table 3-42. Voltage Drop Using Wire Area (mm ) ..................
  • Page 8 Released Manual 35136 GS Series Warnings and Notices Important Definitions This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. DANGER - Indicates a hazardous situation, which if not avoided, will result in death or serious injury.
  • Page 9 • 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 RoHS Directive: Restriction of Hazardous Substances 2011/65/EU: Woodward Turbomachinery Systems products are intended exclusively for sale and use only as a part of Large-Scale Fixed Installations per the meaning of Art.2.4(e) of directive 2011/65/EU. This fulfills the requirements stated in Art.2.4(c) and as such the product is excluded from the scope of RoHS2...
  • Page 11 Class I, Zone 2, AEx ec IIC T3 Gc for United States Certificate 70218547 Some models in the GS Series family have a limited CSA certification under UL 429 and CSA C22.2 No. 139. The limitation corresponds to which valve...
  • Page 12 7. Internal field wiring is to be installed in accordance with instructions detailed in this user manual. Field wiring for the GS Series valves must be suitable for at least 105C for installations using ATEX or IECEx. 115C required for installations using North American (CSA) certification.
  • Page 13 Shields at both sides shall be connected to earth ground. An AC coupling (shield connected to earth ground via R||C components) shall be ensured on at least one side (at GS Series valves or opposite cable end). Connect the ground terminal of the GS Series valve to earth ground.
  • Page 14 Chapter 1. General Information The GS Series is an electrically actuated fuel valve with an on-board electronic driver (DVPII). The self- cleaning, shear-type metering action keeps the metering port free from performance-limiting deposits of gas condensates, contaminants, and system debris. Standard versions are compatible with most gaseous fuels, including natural gas, propane, ethane, methane, and up to 50% hydrogen by volume.
  • Page 15 Released Manual 35136 GS Series Chapter 2. Technical Specifications Valve Characteristics Standard Version: Natural gas Optional H2 Service Version: 99.999% gaseous hydrogen Maximum Gas Supply 750 psig (5170 kPa) - aluminum body Pressure: 1440 psig (9928 kPa) - stainless steel body...
  • Page 16 Released Manual 35136 GS Series Inlet and Discharge Flanges: Alum. body GS40: 1.5 inch (Size -16) SAE J518-1 (Code 61) Alum. body GS50: 2.0 inch (Size -32) SAE J518-1 (Code 61) SST body GS40: NPS 1½ inch ASME B16.5 Class 600 RF SST body GS50: NPS 2 inch ASME B16.5 Class 600 RF...
  • Page 17 Released Manual 35136 GS Series 0.5A max current rating, 32V max contact rating, inductive load rated, 1500 VAC isolation from input power, 500 VAC isolation from chassis Environmental Specifications Electromagnetic Compatibility EN 61000-6-2:2005: Immunity for Industrial Environments (EMC): EN 61000-6-4:2007: Emissions for Industrial Environments Shock: US MIL-STD-810C method 516.2, procedure 1 (10 G Peak, 11 ms...
  • Page 18 Released Manual 35136 GS Series Figure 2-1a. Outline Drawing Stainless Steel GS50 with Conduit Entries Woodward...
  • Page 19 Released Manual 35136 GS Series Figure 2-1b. Outline Drawing Stainless Steel GS50 with Conduit Entries Woodward...
  • Page 20 Released Manual 35136 GS Series Figure 2-1c. Outline Drawing Stainless Steel GS50 with Connectors Woodward...
  • Page 21 Released Manual 35136 GS Series Figure 2-1d. Outline Drawing Stainless Steel GS50 with Connectors Woodward...
  • Page 22 Released Manual 35136 GS Series Figure 2-2a. Outline Drawing Stainless Steel GS40 with Conduit Entries Woodward...
  • Page 23 Released Manual 35136 GS Series Figure 2-2b. Outline Drawing Stainless Steel GS40 with Conduit Entries Woodward...
  • Page 24 Released Manual 35136 GS Series Figure 2-2c. Outline Drawing Stainless Steel GS40 with Connectors Woodward...
  • Page 25 Released Manual 35136 GS Series Figure 2-2d. Outline Drawing Stainless Steel GS40 with Connectors Woodward...
  • Page 26 Released Manual 35136 GS Series Figure 2-3a. Outline Drawing Aluminum GS50 with Conduit Entries Woodward...
  • Page 27 Released Manual 35136 GS Series Figure 2-3b. Outline Drawing Aluminum GS50 with Conduit Entries Woodward...
  • Page 28 Released Manual 35136 GS Series Figure 2-4a. Outline Drawing Aluminum GS40 with Conduit Entries Woodward...
  • Page 29 Released Manual 35136 GS Series Figure 2-4b. Outline Drawing Aluminum GS40 with Conduit Entries Woodward...
  • Page 30 Take care when unpacking the GS Series valves. Check the assembly for signs of damage, such as bent or dented covers, scratches, and loose or broken parts. Notify the shipper and Woodward if damage is found.
  • Page 31 There are two, M8 x 1.25 threaded holes located on the top of all GS Series valves to be used with lifting eyes. Ensure that the lifting eyes are rated for the full weight of the valve. The threaded hole closest to the on-board driver is near the valve’s center of gravity.
  • Page 32 GS Series Mounting It is recommended that the GS Series valves be mounted directly to the piping system using the ANSI or SAE flanges. Consider the strength of the piping system to support the weight of the valves. If the valves are supported by the separate mounting points available on some versions, additional care should be taken not to exceed the flange loads specified below.
  • Page 33 Coordinate axes were defined as follows. This local coordinate system can be utilized to determine if predicted flange loads are acceptable for use with the SAE flanged GS Series valves. Figure 3-3. Local Coordinate System for SAE Flange Load Calculations It is the customer’s responsibility to ensure that the predicted and actual flange loads are within the...
  • Page 34 Released Manual 35136 GS Series For flange loads to be acceptable, the force and the moment when plotted must lie beneath the limiting force-moment line. This must be true for each axis of the flange. Figure 3-4. Allowable Flange Loads for 2-Inch SAE Code 61 Flange Pressure Transducer Locations The inlet piping of the GS40 and GS50 valves must be in accordance with ANSI/ISA-S75.02 as required...
  • Page 35 IP66 rating. Conduit seals must be installed within 18 inches (450 mm) of the conduit entry when the GS Series is used in Zone 1 or Class I, Div. 1 locations. The GS Series valve must be grounded for safety and EMC compliance (see Grounding Requirements below).
  • Page 36 GS Series on board driver, through 1”-11.5 NPT conduit entries in the driver housing. Field wiring for the GS Series valves must be suitable for at least 115 °C. Input power cable shall be rated to 600V; signal and communication cabling shall be rated at 300V.
  • Page 37 Released Manual 35136 GS Series Table 3-2. GS Series Valve Electrical Connections. Driver with Conduit Entries: Earth Ground: Provided through ground lugs on housing Power Input: 90–150, or 18-32 VDC depending on model number (voltage as measured at the driver input terminals)
  • Page 38 Released Manual 35136 GS Series Figure 3-7a. GS Series Conduit Version System Wiring Diagram – Power Input Woodward...
  • Page 39 Released Manual 35136 GS Series Figure 3-7b. GS Series Conduit Version System Wiring Diagram – IO Woodward...
  • Page 40 Released Manual 35136 GS Series Figure 3-7c. GS Series Conduit Version System Wiring Diagram – Dual CAN. Woodward...
  • Page 41 Released Manual 35136 GS Series Figure 3-7d. GS Series Conduit Version System Wiring Diagram – Single CAN. Woodward...
  • Page 42 Released Manual 35136 GS Series Wiring Strain Relief Tie down points and ratcheting tie wraps are provided to secure the wiring to the top of the circuit board cover. This helps prevent wire strain from being transmitted to the connection at the terminal block and to keep the wiring from chafing on the cover when tightening and under vibration.
  • Page 43 Proper input power wiring to the GS Series driver is crucial to its operation. A circuit breaker meeting the power supply requirement may be used for this purpose. Figure 3-9 illustrates the correct and incorrect power cable wiring.
  • Page 44 WRONG A NEGATIVE GROUND SYSTEM IS SHOWN. IF POSITIVE GROUND SYSTEM IS USED, THE SWITCH AND FUSE MUST BE LOCATED IN SERIES WITH BATTERY (-) AND TERMINAL (TB1-2,4) ON THE WOODWARD CONTROL. THE POSITIVE TERMINAL BECOMES CHASSIS GROUND. Figure 3-9. GS Series Driver Power Wiring Recommendation...
  • Page 45 If a single power source is used to supply power to the GS Series driver, jumpers should be used to apply power to both sets of input power terminals. The purpose of these jumpers is to ensure that the power supplied from the source is distributed equally to the two driver inputs.
  • Page 46 CANbus operation. See ISO 11898 series standards and CAN in Automation (CiA) recommendations for further information. The GS Series valve may be controlled via CAN communication. There are two possible CAN modes: 1. The CANopen Single (with or without analog backup): This mode uses CAN port 1 for digital communication.
  • Page 47 A drop line, 3ft (1m) max length, can be used with a tee connector to install the 120 Ω termination resistors at each end of the bus. For the GS Series conduit version, the termination resistor may be installed internally.
  • Page 48 Released Manual 35136 GS Series Table 3-8. CAN Port Connections CAN Port #1 Connections: Conduit Versions: CAN Terminal Block Pin 4 (CAN1_High) and Pin 3 (CAN1_Low) CAN Terminal Block Pin 2 (CAN1_Com) CAN Terminal Block Pin 1 (CAN1_Shld) CAN Port #2 Connections:...
  • Page 49 GS Series driver. However, the shield must also be directly terminated to chassis (Earth) at one point in the network. In the case of Woodward equipment, the direct ground is meant to be located at the user’s control end, as it exits the user’s control enclosure.
  • Page 50 GS Series Analog Inputs The analog inputs on the GS Series driver are 4–20 mA input that may be used as the position command input. The redundancy settings to determine which input(s) is used, and whether it is the primary or secondary position command is configured using the PC Service Tool.
  • Page 51 Released Manual 35136 GS Series Table 3-14. Wiring Requirements Required Cable Type: Individually shielded twisted pair cable Keep this and all other low-level signal cables separated from motor cables and input power cables to avoid unnecessary coupling (noise) between them...
  • Page 52 Analog Outputs The Analog Outputs from the GS Series driver are 4–20 mA outputs which can be configured to perform one of many different tasks, such as reporting actual position or the demand position. The configuration is done through the PC Service Tool. These outputs are designed for monitoring and diagnostic purposes only and are not meant for any type of closed loop feedback.
  • Page 53 Released Manual 35136 GS Series Analog Output 1 / 2 +24VAO Processor 4-20 mA control system feedback A O_GND DGND (primary 1+/2--, secondary 4+/5-). A O_GND Figure 3-13. Analog Output Interface Diagram Figure 3-13 shows AOUT interface structure. Refer to Figures 3-7b for analog output wiring recommendations at system level.
  • Page 54 Released Manual 35136 GS Series Table 3-17. Analog Output Wiring Requirements Required Cable Type: Individually shielded twisted pair cable Keep this and all other low-level signal cables separated from motor cables and input power cables to avoid unnecessary coupling (noise) between them...
  • Page 55 Released Manual 35136 GS Series Discrete Inputs There are three discrete inputs available. These are designed as pull-down circuits which create a configurable logic level state when an external contact is closed. If the external contact is closed, this pulls the sensing signal down to the low state. If the contact is open, the internal +24VISO source pulls the sensing signal to the high state.
  • Page 56 Released Manual 35136 GS Series Table 3-18. Discrete Input Connections Discrete Input #1 Connections: Conduit Version: Discrete I/O Terminal Block Pin 10 (DI 1) to DI GND (Pin 13-15) Discrete Input #2 Connections: Conduit Version: Discrete I/O Terminal Block Pin 11 (DI 2) to DI GND (Pin 13-15)
  • Page 57 GS Series Discrete Outputs There are three discrete outputs for the conduit version of the GS Series driver. These outputs can be configured to react to any or all the Alarms/Shutdowns in the positioner. The outputs can also be configured as active on or active off. These outputs are low side open-drain drivers requiring an external supply for energizing the external relay or load.
  • Page 58 Released Manual 35136 GS Series Table 3-23. Wiring Requirements Recommended Wire Type: Individually shielded twisted pair cable Keep this and all other low-level signal cables separated from motor cables and input power cables to avoid unnecessary coupling (noise) between them...
  • Page 59 Released Manual 35136 GS Series Discrete outputs can be used to provide feedback on unit alarm/shutdown status. Discrete Output Configuration Options: Turned off: Discrete output is not used (disabled). Active when diagnostic is detected: Output activated when any of the conditions described below is detected.
  • Page 60 GS Series Ethernet Service Port The GS Series driver has an Ethernet service communications port to support operation of the PC Service Tool. This tool is essential for configuration, service support, and firmware updates. The wiring requirements are defined below.
  • Page 61 GS Series Driver Version with Circular Connectors A version of the GS Series valve is available to permit marshaling to the control system via circular connectors which are integrated into the driver housing. Connection can be easily made using the Power, CAN, and Multifunction signal cables.
  • Page 62 Table 3-28. GS Series Valve Electrical Connections Driver with Connectors: Earth Ground: Provided through ground lugs on housing Power Input: 90–150 VDC measured at the GS Series valve CAN Network: CANOpen CAN ports (2) Analog Input: 4–20 mA signal (1 input) Analog Output: 4–20 mA signal (1 output)
  • Page 63 GS Series Cable Assemblies - General Information The Woodward designed cable assemblies are water and oil resistant to type MIL-23699 synthetic oil, splashing rating, and comply with low smoke requirements per NFPA 262 (UL 910). The construction of the cables assemblies prevents gas and vapor migration. The general characteristics of these cables is listed below: Table 3-29.
  • Page 64 Released Manual 35136 GS Series Table 3-32. CAN Drop Cable Orderable Part Numbers Single CAN Drop Cable Dual CAN Drop Cable Woodward PN Cable Length Woodward PN Cable Length 5450-2219.2 2 ft 5450-2245.2 2 ft 5450-2219.3 3 ft 5450-2245.3 3 ft 5450-2219.4...
  • Page 65 Released Manual 35136 GS Series Table 3-36. Multifunction Cable General Specification Cable Rating: 300V UL PLTC RATING Ethernet Pairs: CAT5e 24 AWG, 2 pair per ANSI/TIA/EIA-568. I/O Data Pairs: 20 AWG, 19 strands, individually tinned Drain / Shield Wire 20 AWG, 19 strands, individually tinned...
  • Page 66 Released Manual 35136 GS Series Front Panel Connectors Installation Follow the instructions below to ensure the front panel connectors are properly mated. The multifunction cable should be installed first, then the CAN cable, and finally the power cable. CAN and I/O Signal Connectors Install threaded MIL connectors cables in accordance with Figure 3-18.
  • Page 67 Released Manual 35136 GS Series Figure 3-20a. GS Series Connector Version System Wiring Diagram – Power Input Woodward...
  • Page 68 Released Manual 35136 GS Series Figure 3-20b. GS Series Connector Version System Wiring Diagram – IO Woodward...
  • Page 69 Released Manual 35136 GS Series Figure 3-20c. GS Series Connector Version System Wiring Diagram – Dual CAN Woodward...
  • Page 70 Released Manual 35136 GS Series Figure 3-20d. GS Series Connector Version System Wiring Diagram – Single CAN Woodward...
  • Page 71 Grounding Requirements The GS Series driver chassis is intended to be grounded using a short, low-impedance strap or cable (typically >12 AWG/4 mm² and <18”/46 cm in length) connected to the designated EMC ground terminal ). Green/yellow insulation and green insulation shall not be used for the EMC ground connection.
  • Page 72 Manual 35136 GS Series Proper input power wiring to the GS Series driver is crucial to its operation. A circuit breaker meeting the power supply requirement may be used for this purpose. Figure 3-21 illustrates the correct and incorrect power cable wiring.
  • Page 73 A guideline for allowable voltage drop is to size the wire for <10% of the nominal voltage under maximum transient conditions. The power input cable provided by Woodward for the connector version of the driver is made of 12 AWG wires. Total voltage drop is the sum of the voltage drops across the power cable and extension cable.
  • Page 74 Provisions for separate, redundant power supplies are provided by dual inputs. Each of the inputs is diode isolated from the main input bus. If one of the power supplies fails, the GS Series driver will continue to operate normally using the functioning power supply. The failure of one power supply will be annunciated as an alarm.
  • Page 75 Released Manual 35136 GS Series The CAN communication baud rate can also be configured using the PC Service Tool. The following are the recommended maximum cable lengths for the various baud rates. Differences in the baud rate and the cable length affect the number of units that can be put onto a network.
  • Page 76 Released Manual 35136 GS Series Table 3-44. Dual / Single CAN Port Connections M83723/83G1610N CAN Port #1 Connections: CAN Front Connector Pin 5 (CAN1_High) and Pin 6 (CAN1_Low) CAN Front Connector Pin 1 (CAN1_Com) CAN Front Connector Pin 4 (CAN1_Shld)
  • Page 77 GS Series driver. However, the shield must also be directly terminated to chassis (Earth) at one point in the network. In the case of Woodward equipment, the direct ground is meant to be located at the user’s control end, as it exits the user’s control enclosure.
  • Page 78 Analog Input The analog input on the GS Series driver is 4–20 mA that may be used as the position command input. The configurability for if the input is used and determining whether it is the primary or secondary position command is done through the PC Service Tool.
  • Page 79 Released Manual 35136 GS Series Table 3-51. Analog Input Specification Analog 4–20 mA: Range is 0 to 25 mA Input Impedance: 200± 20Ω Maximum Temperature Drift: 200 ppm/°C Calibrated Accuracy: ±0.025mA (±0.1% of 25mA Full Scale at 25°C) ±0.063mA (±0.25% of 25mA Full Scale, -40°C - 110°C)
  • Page 80 Released Manual 35136 GS Series Scaler for the 4 to 20 mA input. This is the higher position value Position at max. mA Input Setting corresponding to the max input value in mA. Analog input low diagnostic setting. If the input value is below this setting an error flag is set.
  • Page 81 Analog Output The Analog Output from the GS Series driver is a 4–20 mA output that can drive load resistances up to 500Ω. This output can be configured to perform one of many different tasks, such as reporting the actual position or command set-point position.
  • Page 82 Released Manual 35136 GS Series Table 3-55. Analog Output Specification Output Range: 0.1 to 25 mA Calibrated Output Range: 2 to 22 mA Load Range: 0 Ω up to 500 Ω Calibrated Accuracy: ±0.025mA (±0.1% of 25mA full scale at 25°C) ±0.125mA (±0.5% of 25mA full scale, -40°C - 110°C)
  • Page 83 Released Manual 35136 GS Series Motor current at Min Min motor current value for scaling from motor current to mA Current Scaling Motor current at Max Max motor current value for scaling from motor current to mA Current Scaling Min Current Scaler...
  • Page 84 Released Manual 35136 GS Series Figure 3-26 shows DIN interface structure. Refer to Figure 3-20b for discrete input wiring recommendations at the system level. Table 3-57. Discrete Input Connections Discrete Input #1 Connections: M83723/83G1624N Multifunction Front Connector Pin 19 (DIN1+) and Pin 20 (DIN1-)
  • Page 85 Real-time Software Version on Dashboard tab. Discrete Output There is one Discrete Output for the connector version of the GS Series driver. This output can be configured to react to any or all the Alarms/Shutdowns in the positioner. The output can also be configured as active on or active off.
  • Page 86 Released Manual 35136 GS Series Table 3-61. Discrete Output Connections M83723/83G1624N Discrete Output #1 Connections: Multifunction Front Connector Pin 14 (DOUT1+) and Pin 13 (DOUT1-) Multifunction Front Connector Pin 4 (DOUT Shld) Discrete Output #2 Connections: Not Available Discrete Output #3 Connections: Not Available Table 3-62.
  • Page 87 50 x 0.044 = 2.2V. It is important to select appropriate DOUT cable gage to meet system specifications for long cable lengths. DOUT lines within multifunction cables provided by Woodward for the connector version of the driver is made of 20 AWG wires. Total voltage drop is the sum of the voltage drops across multifunction cable and extension cable.
  • Page 88 Released Manual 35136 GS Series Discrete Output can be used to provide feedback on unit alarm/shutdown status. Discrete Output Configuration Options: Turned off: Discrete output is not used (disabled). Active when diagnostic is detected: Output activated when any of the conditions described below is detected.
  • Page 89 Released Manual 35136 GS Series Ethernet Service Port The GS Series driver has an Ethernet service communications port required for product configuration, service support, and firmware updates. The wiring requirements are defined below. Ethernet Interface Multifunction Cable Ethernet Cable Comm...
  • Page 90 Released Manual 35136 GS Series Chapter 4. Description of Operation Operating Modes The valve can be in four operational modes: Running • Shutdown • Shutdown Position • • Shutdown System Running: In this mode the valve is operating normally and is in position control.
  • Page 91 If the unit remains in this state and is not currently being programmed, then contact Woodward technical support. • Red flashing (red LED on-and-off 3 times per second or faster) – this indicates a low-level self-test failure during initialization. Contact Woodward technical support. Woodward...
  • Page 92 Driver Configuration Overview The GS Series actuator utilizes an ethernet network to support the PC Service Tool, so it is important to understand some networking principals. For successful operation, please read this chapter in detail. Consult with your Network System Administrator for any limitations on the networking allowances in your facility.
  • Page 93 GS Series driver starts at 169.254.100.100. The following diagrams illustrate the different networking options. If the GS Series driver is power cycled it may request a new link local address, typically with the new address going back to 169.254.100.100. However, this number can dynamically increment to 169.254.100.101 and upward depending on network activity, so the user may need to check additional...
  • Page 94 Figure 5-1. Single Valve Link Local For a system with multiple valves, a router can be used. A secure router configuration that is recommended by Woodward for initial connection and configuration is shown in Figure 5-2. Multi Valve Local Point to Point Connection...
  • Page 95 Figure 5-4. Router DHCP Defined by User Network Assignments Static IP Addressing The GS Series driver also supports static IP addressing. IP addressing configuration is managed through the Service Tool “Functions” menu. Special care must be taken when addressing GS Series drivers using static IP.
  • Page 96 GS Series Cyber Security The GS Series driver was developed from the ground up with a critical focus on cyber security. This section details the security features of the driver and how it can be used securely within an overall Defense-in-Depth (DiD) framework.
  • Page 97 Monitoring – This is the basic user level with read access only. This user is not able to shutdown or • reset the GS Series driver. Service Tool screen access always starts with the Monitoring role level. • MonitoringPlus – This is the same as the Monitoring user role with the additional capability to shutdown and/or reset the GS Series driver.
  • Page 98 Google Chrome or Microsoft Edge using a PC for GS Series driver connections. Internet Explorer is not supported. Once the IP address of the GS Series driver is determined, as described in the “Driver Networking & Connections” manual section, its IP address can be entered into the web browser. Connection to the specific GS Series driver of interest must be verified by ensuring the network “Host Name”...
  • Page 99 GS Series User Login Assignments Configuration of the GS Series driver, user management, and software updates requires login to the driver. The login window is accessed by selecting the “User” login button in the top right corner of the Service Tool screen. Follow the “User Account Management” section of the manual and the video for account assignment information.
  • Page 100 Released Manual 35136 GS Series Host Discovery Host discovery is a utility that can be used to find multiple networked drivers. Navigation to this utility is managed by selecting the side menu by pressing the collapsed menu icon. The utility will scan for drivers between the ‘begin’ and ‘end’ IP addresses.
  • Page 101 Released Manual 35136 GS Series Confirming Correct Operation After connecting and setting up the necessary user roles and passwords, verify that the device is operating normally. Review the dashboard tab and the bottom panel where the word “Overview” appears. If the field is green, the unit is operating normally. If there are any detected alarms or faults, they will be displayed in the lower panel.
  • Page 102 Released Manual 35136 GS Series Figure 5-12. Demand Selector To change the manual position setpoint, select the Monitor tab. Then select the Position Demand panel and input the desired value in the Manual Position Demand Input Field. The pencil symbol indicates this is an input field.
  • Page 103 Manual 35136 GS Series Quick Start Guide The GS Series driver includes built-in documentation to guide the user through the device configuration process. The quick-start guide can be accessed by opening the left menu and selecting “Quick Start Guide”. Selecting the Quick Start...
  • Page 104 Released Manual 35136 GS Series Chapter 6. Valve Sizing Determination of Effective Area To confirm that the sizes of the GS valves are appropriate for the application, the effective area required to meet the maximum flow requirement must first be determined. The flow rate attainable under a given set of process fluid conditions are constrained by the values of inlet pressure, inlet temperature, discharge pressure, and gas properties.
  • Page 105 For applications requiring high accuracy control, high density numeric tables can also be provided, along with guidance for use with Woodward’s proprietary control algorithms by contacting your Woodward sales associate. Figure 6-1. GS40 Position vs. Effective Area– 0.3SQIN Port Figure 6-2.
  • Page 106 Released Manual 35136 GS Series Figure 6-3. GS50 Position vs. Effective Area – 1.0SQIN Port Figure 6-4. GS50 Position vs. Effective Area – 1.5SQIN Port Woodward...
  • Page 107 Figure 6-5. Position vs. GS50 Effective Area – 2.0SQIN Port Seat Leakage All GS Series valves meet ANSI/FCI 70-2 Class IV seat leakage. At elevated pressure differentials, the seat leakage will increase as shown in the graph below. Figure 6-6. High Differential Pressure Seat Leakage for GS40 and GS50...
  • Page 108 The overboard vent drain (OBVD) on all GS valves provides a connection where all leakage from the valve stem seals can be routed to a safe area or flare. The stem seals of the GS Series valves are exposed to the downstream pressure (P2) of the metering valve. All GS Series valves are factory tested to ensure the stem seals do lot leak more than 13.5 SCCM when new, although vast majority of new GS...
  • Page 109 Introduction This chapter addresses several possible causes and recommended actions for many common problems that may be encountered with a system including the GS Series valve, GS Series driver, power source and interconnect wiring. Incorrect settings may adversely affect the performance, accuracy, behavior, and safety of the valve/actuator/positioner system.
  • Page 110 Released Manual 35136 GS Series DVPII Troubleshooting Guide I/O Diagnostics Table 7-1. DVPII Troubleshooting Guide I/O Diagnostics Diagnostic Indications Probable Causes Recommended Action Power–up Reset It is normal for the Power Up Reset Issue a reset to the DVPII. diagnostic to occur upon power up of the Detection: DVPII.
  • Page 111 Internal problem with the electronics. Contact Woodward Technical Support for further assistance. Detection: If the internal bus voltage sensor is at min. GS Series Driver IGBT Short Internal problem with the electronics. Contact Woodward Technical Error Support for further assistance. Detection: If one of the driver IGBT’s is in a...
  • Page 112 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions Current Diagnostic 1 or Current Diagnostic 2 Electrical or wiring problem Determine if wiring is correct, or Current Diagnostic 3 see Chapter 3. The DVPII current sense circuit has failed...
  • Page 113 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions Digital Com 1 & 2 and/or Analog Backup Error Detection: Lost signals or wiring problem. Check wiring. Verify signals in When CANopen demand is used, Service Tool. indicates the position setpoint is failed.
  • Page 114 Released Manual 35136 GS Series Internal Diagnostics Table 7-2. DVPII Troubleshooting Guide Internal Diagnostics Diagnostic Indications Probable Causes Recommended Actions Input Voltage 1 High Power supply and/or setting incorrect for Check input voltage and application. correct voltage to within Input Voltage 2 High specification limits.
  • Page 115 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions Electronics Temperature Low The ambient temperature of the driver is Increase ambient temperature lower than allowed by specification. to within specification limits. Detection: The temperature sensor is defective. Contact Woodward Technical The Control Board temperature Support for further assistance.
  • Page 116 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions No IO Board Found DVPII internal electronics failure or there is Contact Woodward Technical no I/O board connected. Support for further assistance. Detection: During power up the control board will read the I/O board.
  • Page 117 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions 1.35 Volt Supply Failed Internal electronics failure. Contact Woodward Technical Support for Detection: further assistance. Internal 1.35 V is outside acceptable range. 2.5 Volt Supply Failed Internal electronics failure.
  • Page 118 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions RealTime CPU GroupX ADC 3V3 Internal electronics failure. Contact Woodward Failed Technical Support for (X can be 0, 1, 2, 3, 4, 5, or 7) further assistance. Detection: Internal 3.3 V is not being converted to the proper value by ADC identified by group “X”.
  • Page 119 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions FPGA Communication Error There is a problem with communication from Contact Woodward the FPGA device to the CPU. Technical Support for Detection: The FPGA-to-CPU further assistance. communication has failed runtime diagnostics.
  • Page 120 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions RealTime CPU Fatal Initialization Internal electronics failure. Contact Woodward Error Technical Support for further assistance. Detection: The real-time CPU encountered a fatal issue during initialization. Note: The occurrence of this error...
  • Page 121 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions Reduced Torque Error User Force Limiter is active. This could be proper/expected operation Detection: or User Force Limiter This status flag indicates the settings could be incorrect. system torque has been reduced Current limiter on motor is active.
  • Page 122 10% and 95% of max output. The gain is continually adjusted by the DVPII. The DVPII position feedback input circuit Contact Woodward Technical Support has failed. for further assistance. Motor 1 Excitation Error The excitation wiring to the resolver is Check the resolver excitation coil shorted or intermittent.
  • Page 123 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions Valve Shaft 1 and 2 Res. Valve Shaft 1 error is true if any of the If there is a Valve Shaft 1 and 2 error, Error following errors are detected:...
  • Page 124 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions Control Model Not Running DVPII detected a problem that will not allow the Using the Service Tool, Detection: position controller to run. identify and correct the This status flag indicates issues.
  • Page 125 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions ID Module Not Detected Failure to read the ID module on the valve/actuator See associated diagnostics system. on the Valve Type Detection: Selection Screen in the During power up the ID Service Tool.
  • Page 126 Detect diagnostic is also set calibration records are corrupt in when this condition is the ID module. Contact detected. Woodward Technical Support for a copy of the correct parameter file. Valve Serial Number will need to be provided. Incorrect Power Board...
  • Page 127 DVPII. See recorded. This associate valve manual for resistance diagnostic occurs if the values. Valve Shaft resolver Contact Woodward Technical Support for reading is detected further assistance if readings are out of outside the calibrated valve specifications. resolver range.
  • Page 128 The difference between difference error. the resolver readings is One or both resolvers have moved. Contact Woodward Technical Support larger than the for further assistance. permissible shutdown There is an electrical problem with the See Position Resolver Diagnostics limit value.
  • Page 129 This operation. Record results from multiple diagnostic occurs if the power ups. Contact Woodward motor resolver is not Technical Support for further within the calibrated assistance.
  • Page 130 The fusible link on the valve is damaged. max mechanical stop for correct initialization, the DVPII operation. Record results from multiple verifies that the valve is power ups. Contact Woodward at the min stop. This Technical Support for further diagnostic occurs if the assistance.
  • Page 131 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions Startup Close Shaft 1 Calibration values specific to the Use the auto detection function or Error valve/actuator serial number are incorrect as download the valve specific stored in the DVPII.
  • Page 132 Released Manual 35136 GS Series Diagnostic Indications Probable Causes Recommended Actions Startup Close Shaft 2 Calibration values specific to the Use the auto detection function or Error valve/actuator serial number are incorrect download the valve specific as stored in the DVPII.
  • Page 133 1 Error Heat Sink Temp. Sensor DVPII internal electronics failure or extreme If DVPII temperature is within 2 Error temperature. specified limits, contact Woodward Technical Support for further Detection: assistance. This fault status flag indicates power board heat sink sensor (1 or2)
  • Page 134 Table 7-9. DVPII Troubleshooting Guide Watchdog Diagnostics Diagnostic Indications Probable Causes Recommended Actions Watchdog Critical Internal electronics failure. Contact Woodward Technical Support Process Error for further assistance. Please provide information on the presence of any of Detection: the possible source errors in the The real-time CPU has “Stored Alarms and Shutdowns”...
  • Page 135 GS Series Diagnostic Indications Probable Causes Recommended Actions ECC Uncorrected Internal electronics failure. Contact Woodward Technical Support Critical Memory Error for further assistance. Please provide information on the presence of any of Detection: the possible source errors in the The real-time CPU has “Status Flags”...
  • Page 136 Due to typical noise levels in turbine environments, hearing protection should be worn when working on or around the GS Series valves. The surface of this product can become hot or cold enough to be a hazard.
  • Page 137 Service Distributor or the OEM or Packager of the equipment system, based on the standard Woodward Product and Service Warranty (Woodward North American Terms and Conditions of Sale 5-09-0690) that is in effect at the time the product is originally shipped from Woodward or a service is performed: Replacement/Exchange (24-hour service) •...
  • Page 138 All repair work carries the standard Woodward service warranty (Woodward North American Terms and Conditions of Sale 5-09-0690) on replaced parts and labor.
  • Page 139 The unit serial number, which is also on the nameplate • Engineering Services Woodward offers various Engineering Services for our products. For these services, you can contact us by telephone, by email, or through the Woodward website. Technical Support •...
  • Page 140 GS Series Technical Assistance If you need to contact technical assistance, you will need to provide the following information. Please write it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the Woodward factory: General...
  • Page 141 Long-Term Storage Requirements Units that will not be put into service within twelve months should be packaged for long-term storage as described in Woodward manual 25075, Commercial Preservation Packaging for Storage of Mechanical- Hydraulic Controls. Recommended long term storage temperature for longest life: +25°C +/- 10°C.
  • Page 142 Further detailed information regarding CANopen can be obtained at www.can-cia.org. Information about CAN is available in ISO 11898. Specific information regarding DVPII behavior is detailed below. The DVPII CANopen Electronic Data Sheet (EDS) can be downloaded from www.woodward.com/software. A.2 Network Architecture...
  • Page 143 Released Manual 35136 GS Series A.3 NMT Master Functions There are four distinct functions the master can perform. The slave units will respond to these functions. NMT Block Diagram (Woodward Implementation) Start All Nodes Operating State Start All Nodes Management...
  • Page 144 Released Manual 35136 GS Series The above state diagram is taken from the CANopen specification. Initialization: NMT and DVPII: The initialization state is used to open the CAN ports and to initialize the CANopen stack. After this is done the DVPII or NMT will go to the pre-operational state automatically. It will send the boot-up message.
  • Page 145 All SDO data will be requested when the NMT master goes from Pre-Operational to Operational. Woodward gives the designed application the option to request all information under application control. This is to ensure that when the slave devices are powered, cycled, or added, their information gets updated.
  • Page 146 Released Manual 35136 GS Series Timing: In a timing diagram, the process will look like this: NMT Master in Operational state Timeout Time NMT Master NMT Master Transmits SDO Request NMT Master Receives SDO Response NMT Master Transmits SDO Request...
  • Page 147 To make sure the CAN bus is not overloaded, the NMT master must send slow messages at a rate that will allow all messages to be sent and received. Woodward spaces the messages so that all slaves are addressed once every 750 ms.
  • Page 148 Released Manual 35136 GS Series Timing: In a timing diagram, the process will look like this: 50 mSec 10 mSec Frame 10 mSec Frame NMT Master 2mSec 2mSec 2mSec 2mSec 2mSec 2mSec 2mSec 2mSec 2mSec 2mSec 2mSec NMT Master Transmits synch...
  • Page 149 CANopen Network. Example: In Woodward controllers, one FRAME is defined by the rate group that is specified in the CANopen interface block. This is typically 10 ms but can also be 5 ms, 20 ms, 40 ms, or 80 ms.
  • Page 150 Released Manual 35136 GS Series Simple Block Diagram to Define Frame Time Frame time is the time that it takes for the turbine controller to sample the inputs, execute the main application code, and send the SYNC message out on the CANopen network.
  • Page 151 Released Manual 35136 GS Series Table A-1. Transmit PDO Summary Id base Tx PDOs Name Byte Message or Data Type Mfr # hex 0x180 PDO1 Fast Message Sync Actual Position uint16 2034 Actual Current uint16 2035 Status Bits (0-5 used – 6 &7...
  • Page 152 Released Manual 35136 GS Series Table A-2. Receive PDO Summary The manufacturer numbers given here for SDO access are for reference only. SDO writes aren’t supported; the data must be written with the PDOs. Id base (hex) PDOs Name Byte Type...
  • Page 153 Released Manual 35136 GS Series A.5 Receive (Rx) PDO Definitions Data length must be sent as specified. Receive PDO 1 – Realtime “Fast Message” with Demand and Command Bits This and a sync message need to be received within the timeout milliseconds.
  • Page 154 Released Manual 35136 GS Series Position Error Motor Shutdown Time (uint16) • Position Error Shaft Alarm Time (uint16) • Position Error Shaft Shutdown Time (uint16) • Byte 4: Command Byte 2 Data length: 1 byte Bit 0: Auto Detect Request. If this bit is "1", it indicates an auto-detection is requested. This is only honored if the valve type state is set to ValveTypeStateSerialValveTypeFailed.
  • Page 155 Released Manual 35136 GS Series Byte 5-8: Resolver Shutdown Difference Error value Data length: 4 bytes, Float. Units: Range: 0 to 100% Receive PDO 4 – Slow Message: #3 Difference Alarm and Shutdown Times Message type: “ASYNC” COB Id: 1280+Node Id (0x500+NodeId)
  • Page 156 Released Manual 35136 GS Series Byte 5-8: Position Error Motor Shutdown Limit Data length: 4 bytes, Float Units: Range: 0 to 110% Receive PDO 7 – Slow Message: #6 Position Error Shaft Alarm and Shutdown Limits Message type: “ASYNC” COB Id:...
  • Page 157 Released Manual 35136 GS Series A.6 Transmit (Tx) PDO Definitions There is only one (1) "Fast Message" sent from the DVPII. There are additional "Slow Message" sent for monitoring purposes. Transmit PDO 1 – Actual Position, Current and Status from Valve...
  • Page 158 Released Manual 35136 GS Series Data: Byte 1-4: Input Voltage1 Data length: 4 bytes, Float. Units: Volts Byte 5-8: Input Voltage2 Data length: 4 bytes, Float. Units: Volts Transmit PDO 4 – Slow Message #3: Actual Position 1 / Actual Position 2 Message type: Transmitted 4 ms after receipt of Receive PDO 2.
  • Page 159 Released Manual 35136 GS Series Table A-3. PDO6 Byte 1-2 (Status Error Register 20) Status Status Name Description Troubleshooting Guide Byte Byte 1-2 Bit 0 Security Lockout Active Write access via service tool is None disabled. Byte 1-2 Bit 1...
  • Page 160 Released Manual 35136 GS Series Status Status Name Description Troubleshooting Guide Byte Byte 1-2 Bit 14 Discrete Output #1 On Discrete output #1 state is True. The True state can occur when the detected contact is closed or Byte 1-2...
  • Page 161 Released Manual 35136 GS Series Status Status Name Description Troubleshooting Guide Byte Byte 5-6 Bit 5 Manual/External Shutdown The Shutdown Position mode has See Shutdown Position Position been invoked from one of the user interfaces. Byte 5-6 Bit 6 High Electronics...
  • Page 162 Released Manual 35136 GS Series Status Status Name Description Troubleshooting Guide Byte Byte 7-8 Bit 15 Phase B Input Current Phase B current sensor has failed See Current Phase B Sensor High Fault at high output. Sensor High Transmit PDO 7 – Slow Message #6: Status Error Flags Set 2 Message type: Transmitted 10 ms after receipt of Receive PDO 2.
  • Page 163 Released Manual 35136 GS Series Table A-8. PDO7 Byte 3-4 (Status Error Register 5) Status Status Name Description Troubleshooting Guide Byte Byte 3-4 Bit 0 Motor 1 Sine Error Detected fault based on the Motor See Motor 1 Sin Error 1 Sine signal value.
  • Page 164 Released Manual 35136 GS Series Status Status Name Description Troubleshooting Guide Byte Byte 5-6 Bit 1 Heat Sink Temp. Sensor 2 The #2 temperature sensor on the None - Replace DVPII Error (Applies only to DVPII Heat Sink is out of range/faulted.
  • Page 165 Released Manual 35136 GS Series Status Status Name Description Troubleshooting Guide Byte Byte 5-6 Bit 15 Watchdog Service Link A watchdog timeout occurred on a See Watchdog Service Error software process for Service Link Link Error communication. Table A-10. PDO7 Byte 7-8 (Status Error Register 14)
  • Page 166 See Dual Resolver Diff Alarm. Byte 1-2 Bit 6 Dual Resolver Difference The readings between the two Contact Woodward for a Shutdown motor commutation resolvers spare actuator/valve. differs by an amount larger than the shutdown threshold for a given See Dual Resolver Diff valve type.
  • Page 167 DVPII. Byte 1-2 Bit 8 Shaft 2 Range Limit Error The reading of the valve or actuator Contact Woodward for a secondary final element position spare actuator/valve. sensor is out of range. See Shaft 1 Range Limit Error or Shaft 2 Range Limit Error.
  • Page 168 Released Manual 35136 GS Series Table A-12. PDO8 Byte 3-4 (Status Error Register 9) Status Status Name Description Troubleshooting Guide Byte Byte 3-4 Bit 0 Startup Close Motor 2 Error This indicates the Motor 2 resolver See Startup Close Motor...
  • Page 169 Released Manual 35136 GS Series Table A-13. PDO8 Byte 5-6 (Status Error Register 21) Status Status Name Description Troubleshooting Guide Byte Byte 5-6 Bit 0 Zero Cutoff Active This is a status enunciation only. Status Only This bit is active when the actuator...
  • Page 170 Output Configuration. CANopen Objects The following section provides information on the CANopen objects supported by the DVPII. The product EDS file (Woodward part number 9927-1518) is available for download on the Woodward website (www.woodward.com). Table A-14. CANopen Standard Objects Supported...
  • Page 171 > SubIndex 6: Valve Revision number (Woodward valve product revision number). Valve revision level represents the Woodward valve part number revision where 1=rev NEW or -, 2=rev A, 3=rev B, etc. Values of 100 or higher indicate a preliminary revision (101=rev 1, 102=rev 2, etc).
  • Page 172 - Internal field wiring is to be installed according to instructions detailed in this user manual. Field wiring for the GS Series valves must be suitable for at least 105C for installations using ATEX or IECEx. 115C is required for installations using North American (CSA) certification.
  • Page 173 Revisions to Chapter 5: • Revised Driver Configuration Overview in Chapter 5 Added Initial Connection to the GS Series Valves Revised Figures 5-1 through 5-4 and 5-11 through 5-14 Revised Table 5-2 Revised Service Tool Overview, User Login Assignments, Driver Utilities, User Management,...
  • Page 174 IECEx Changed North American Compliance to PENDING Changed content in first paragraph in Special Conditions for Safe Use • Changed temperature rating for Field Wiring for GS Series in Specific Conditions of Use for IECEx • and ATEX • Change the VDC at the end of the second paragraph of Chapter 1 •...
  • Page 175 Released Manual 35136 GS Series Declarations Woodward...
  • Page 176 Released Manual 35136 GS Series Woodward...
  • Page 177 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. Complete address / phone / fax / email information for all locations is available on our website.

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