Woodward ELA 150 User manual

Product Manual 35183

(Revision -, 5/2022)

Original Instructions

Electric Linear Actuator (ELA)

ELA 150 Base Mount

Installation and Operation Manual

Released

General

Precautions

Read this entire manual and all other publications pertaining to the work to be

performed before installing, operating, or servicing this equipment.

Practice all plant and safety instructions and precautions.

Failure to follow instructions can cause personal injury and/or property damage.

Revisions

This publication may have been revised or updated since this copy was produced.

To verify that you have the latest revision, check manual

26455

, Customer

Publication Cross Reference and Revision Status & Distribution Restrictions, on

the publications page of the Woodward website:

www.woodward.com/publications

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 receive the latest cop

Proper Use

Any unauthorized modifications to or use of this equipment outside of its

specified mechanical, electrical, or other operating limits may cause personal

injury and/or property damage, including damage to the equipment. Any such

unauthorized modifications: (i) constitute "misuse" and/or "negligence" within

the meaning of the product warranty, thereby excluding warranty coverage for

resultin

dama

e, and

(

)

invalidate product certifications or listin

Translated

Publications

If the cover of this publication states "Translation of the Original Instructions"

please note:

The original source of this publication may have been updated since this

translation was made. Be sure to check manual

26455

, Customer Publication

Cross Reference and Revision Status & Distribution Restrictions, to verify whether

this translation is up to date. Out-of-date translations are marked with . Always

compare with the original for technical specifications and for proper and safe

installation and operation procedures.

Revisions— A bold, black line alongside the text identifies changes in this publication since the

last revision.

The following are trademarks of Woodward, Inc.:

ProTech

Woodward

The following are trademarks of their respective companies:

Modbus (Schneider Automation Inc.)

Pentium (Intel Corporation)

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.

Manual 35183

Released

Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount

Woodward 1

Contents

WARNINGS AND NOTICES ............................................................................................................... 3

ELECTROSTATIC DISCHARGE AWARENESS...................................................................................... 4

REGULATORY COMPLIANCE ............................................................................................................ 5

CHAPTER 1. GENERAL INFORMATION .............................................................................................. 7

CHAPTER 2. SPECIFICATIONS.......................................................................................................... 8

DVP Specifications........................................................................................................................................ 9

CHAPTER 3. INSTALLATION REQUIREMENTS .................................................................................. 10

Introduction ................................................................................................................................................. 10

Mechanical Installation Requirements ........................................................................................................ 10

Electrical Installation Requirements............................................................................................................ 18

Installation and Commissioning Checks ..................................................................................................... 25

CHAPTER 4. PC SERVICE TOOL OPERATION ................................................................................. 26

CHAPTER 5. SET-UP AND OPERATION ........................................................................................... 27

Setting up the DVP and ELA....................................................................................................................... 27

Pre-start and Operational Checks............................................................................................................... 28

CHAPTER 6. DIAGNOSTICS............................................................................................................ 29

CHAPTER 7. MAINTENANCE AND HARDWARE REPLACEMENT......................................................... 30

Maintenance................................................................................................................................................ 30

CHAPTER 8. PRODUCT SUPPORT AND SERVICE OPTIONS .............................................................. 32

Product Support Options............................................................................................................................. 32

Product Service Options ............................................................................................................................. 32

Returning Equipment for Repair ................................................................................................................. 33

Replacement Parts...................................................................................................................................... 34

Engineering Services .................................................................................................................................. 34

Contacting Woodward’s Support Organization ........................................................................................... 34

Technical Assistance .................................................................................................................................. 35

CHAPTER 9. LONG-TERM STORAGE REQUIREMENTS ..................................................................... 36

REVISION HISTORY ....................................................................................................................... 37

DECLARATIONS ............................................................................................................................ 38

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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount

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Illustrations and Tables

Figure 3-1. Vertical Lift Example................................................................................................................. 11

Figure 3-2. Inverted Lift Example................................................................................................................ 11

Figure 3-3. Motor Lift Example.................................................................................................................... 12

Figure 3-4. Unapproved Lifting Example .................................................................................................... 12

Figure 3-5a. ELA 150 Base Mount Dimensions.......................................................................................... 13

Figure 3-5b. ELA 150 Base Mount Dimensions.......................................................................................... 14

Figure 3-5c. ELA 150 Base Mount Dimensions.......................................................................................... 15

Figure 3-6. Position and Adjust Turnbuckle ................................................................................................ 16

Figure 3-7. Secure Turnbuckle Jam Nuts ................................................................................................... 16

Figure 3-8. Lockwire Nuts ........................................................................................................................... 17

Figure 3-9. Manual Drive Access Plug Location......................................................................................... 17

Figure 3-10. Manual Drive Rotation Example............................................................................................. 18

Figure 3-11. Motor Power Cable................................................................................................................. 20

Figure 3-12. Motor Power Cable................................................................................................................. 21

Figure 3-13. DVP Integrated Signal Cable.................................................................................................. 22

Figure 3-14. DVP Integrated Signal Cable.................................................................................................. 23

Figure 3-15. Control Wiring Diagram .......................................................................................................... 24

Table 2-1. ELA 150 Specifications................................................................................................................ 8

Table 3-1. Installation Checklist (Before Power is Applied to the System)................................................. 25

Table 3-2. Pre-operational Checklist (Before Stroking the Actuator).......................................................... 25

Table 5-1. Installation, Pre-operational, Pre-start, and Operational Checks .............................................. 28

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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount

Woodward 3

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.

WARNING - Indicates a hazardous situation, which if not avoided, could result in death or serious

injury.

CAUTION - Indicates a hazardous situation, which if not avoided, could result in minor or moderate

injury.

NOTICE - Indicates a hazard that could result in property damage only (including damage to the

control).

IMPORTANT - Designates an operating tip or maintenance suggestion.

Overspeed /

Overtemperature /

Overpressure

The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against

runaway or damage to the prime mover with possible personal injury,

loss of life, or property damage.

The overspeed shutdown device must be completely independent of

the prime mover control system. An overtemperature or

overpressure shutdown device may also be needed for safety, as

appropriate.

Personal Protective

Equipment

The products described in this publication may present risks that

could lead to personal injury, loss of life, or property damage.

Always wear the appropriate personal protective equipment (PPE) for

the job at hand. Equipment that should be considered includes but is

not limited to:

Eye Protection

Hearing Protection

Hard Hat

Gloves

Safety Boots

Respirator

Always read the proper Material Safety Data Sheet (MSDS) for any

workin

fluid

(

)

and compl

with recommended safet

equipment.

Start-up

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against

runaway or overspeed with possible personal injury, loss of life, or

property damage.

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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount

Woodward 4

Electrostatic Discharge Awareness

Electrostatic

Precautions

Electronic controls contain static-sensitive parts. Observe the

following precautions to prevent damage to these parts:

Discharge body static before handling the control (with power to

the control turned off, contact a grounded surface, and maintain

contact while handling the control).

Avoid all plastic, vinyl, and Styrofoam (except antistatic

versions) around printed circuit boards.

Do not touch the components or conductors on a printed circuit

board with your hands or with conductive devices.

To prevent damage to electronic components caused by improper

handling, read and observe the precautions in Woodward manual

82715

, Guide for Handling and Protection of Electronic Controls,

Printed Circuit Boards, and Modules.

Follow these precautions when working with or near the control.

1. Avoid the build-up of static electricity on your body by not wearing clothing made of synthetic

materials. Wear cotton or cotton-blend materials as much as possible because these do not store

static electric charges as much as synthetics.

2. Do not remove the printed circuit board (PCB) from the control cabinet unless absolutely necessary.

If you must remove the PCB from the control cabinet, follow these precautions:

Do not touch any part of the PCB except the edges.

Do not touch the electrical conductors, connectors, or the components with conductive devices

or with your hands.

When replacing a PCB, keep the new PCB in the plastic antistatic protective bag it comes in

until you are ready to install it. After removing the old PCB from the control cabinet, immediately

place it in the antistatic protective bag.

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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount

Woodward 5

Regulatory Compliance

European Compliance for CE Marking:

These listings are limited only to those units bearing the CE Marking

ATEX – Potentially

Explosive

Atmospheres

Directive:

Directive 2014/34/EU on the harmonisation of the laws of the Member

States relating to equipment and protective systems intended for use in

potentially explosive atmospheres.

Zone 2: II 3 G, Ex ec IIC T3 Gc

EMC Directive Declared to Directive 2014/30/EU of the European Parliament and of the

Council of 26 February 2014 on the harmonization of the laws of the

Member States relating to electromagnetic compatibility (EMC).

Other European Compliance:

Compliance with the following European Directives or standards does not qualify this product for

application of the CE Marking:

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.

ATEX Directive: Exempt from the non-electrical portion of the ATEX Directive 2014/34/EU

due to no potential ignition sources per EN ISO 80079-36:2016 for Zone 2

installation.

Machinery Directive: Compliant as partly completed machinery with Directive 2006/42/EC of the

European Parliament and the Council of 17 May 2006 on machinery.

Other International Compliance:

IECEx Certified for use in hazardous locations

IECEx CSA 15.0032X Ex ec IIC T3 Gc

North American Compliance:

These listings are limited only to those units bearing the CSA mark.

CSA: CSA Certified for Class I, Division 2, Groups A, B, C, & D, T3 at 121 °C

mbient. For use in Canada and the United States. Certificate 70010175

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Explosion Hazard

Do not remove covers or connect/disconnect electrical connectors

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.

Risque d'explosion

Ne pas enlever les couvercles, ni raccorder / débrancher les

prises électriques, sans vous en assurez auparavant que le

système a bien été mis hors tension; ou que vous situez

bien dans une zone non explosive.

La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I, Division 2

et/ou Zone 2.

Special Conditions for Safe Use

Wiring must be in accordance with North American Class I, Division 2, or European or other international

Zone 2, Category 3 wiring methods as applicable, and in accordance with the authority having jurisdiction.

Use supply wires suitable for at least 10°C above surrounding ambient.

Note: Cables supplied through Woodward meet this requirement.

To assure IP55 ingress protection, attach mating connectors to the actuator’s receptacles

Compliance with the Machinery Directive 2006/42/EC noise measurement and mitigation requirements is

the responsibility of the manufacturer of the machinery into which this product is incorporated.

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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount

Woodward 7

Chapter 1.

General Information

The ELA actuation system consists of an electronically controlled linear actuator and a digital electronic

positioner for position control on industrial turbine applications. The digital positioner and actuator

combination are capable of precisely positioning the actuator to follow the setpoint signal from the turbine

control system. The actuator position is controlled by regulating the current to a 3-phase brushless DC

motor, which converts the rotary motion to linear motion via a gear reduction system and leadscrew.

Redundant resolver rotary position transducers are used to sense motor shaft position for commutation

and velocity feedback to the digital positioner. Should one resolver fail, the positioner will revert to the

working sensor to maintain operation.

The Woodward Electric Linear Actuator (ELA) includes the following major sub-assemblies:

A high reliability brushless DC motor

A high load capacity roller screw, driven by a spur gear train

Dual motor resolvers for motor commutation and primary position feedback

An LVDT for independent shaft positioning verification

The Woodward ELA design offers the following benefits to the purchaser in comparison to other electric

actuators:

The actuator and model-based controller provide the accuracy, bandwidth and slew times required for

precise control of the guide vanes. No dynamic tuning is necessary during installation or operation.

The highly capable electronic positioner provides comprehensive diagnostic and communication

functions. These features minimize installation and replacement times and improve system

maintainability.

The Woodward actuator is designed to provide high force consistent with heavy industrial equipment.

All power train and electronic components are designed with conservative design margins for high

reliability. The simple and robust design is capable of consistent performance for extended periods in

challenging environments.

The actuator and digital positioner have been designed to achieve extended Mean Time Between

Overhaul (MTBO) goals. These targets have been reached through the conservative rating of parts

and the careful analysis of individual component and system performance.

An integrated Identification Module (ID module) comes in each actuator. This ID module provides key

information specific to the actuator assembly (i.e., identifies the stroke, gear ratio, motor

characteristics, and device startup limits.) The digital positioner electronically queries the ID module

every time it is powered up. This provides for quick and error free initialization of a new actuator or

digital positioner.

The electronic position controller provides for dual power inputs, and options for redundant digital

interfaces for improved reliability.

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Manual 35183 Electric Linear Actuator (ELA) 150 Base Mount

Woodward 8

Chapter 2.

Specifications

Table 2-1. ELA 150 Specifications

pe Electric Mechanical Actuator

(

EMA

)

Dut

cle Continuous

Stroke Ranges Available (max): 2.000 inch stroke

3.000 inch stroke

Peak Force

(

0.5 seconds

)

* 160 kN / 36 000 lb. bidirectional

Stall Force

(

continuous

)

* 160 kN / 36 000 lb. bidirectional

Continuous Application Force * 105 kN / 24 150 lb. bidirectional

Speed under Opposing Load 2 in: 0.4 in/sec

3 in: 0.6 in/sec

Max Speed @ Zero Force 2 in: 0.4 in/sec

3 in: 0.6 in/sec

Max Motor Input Current 25 A continuous

Input Voltage (to DVP10000) 112–300 VDC absolute min/max 125 Vdc typical

(

see manual 26773

)

Input Current (to DVP10000) –

Max Stead

State1:

2.5 Amps at 15,000 lbf

4.5

mps at 30,000 lbf

Input Current (to DVP10000) –

Max Transient2: 40 Amps for 5 seconds

Accurac

≤±1.0% of full scale

Repeatabilit

Ran

e Within ± 0.5% of full scale

namic Bandwidth > 2 Hz at

–

3 dB 90 de

rees phase loss

Design Life

20 years with overhauls

96,000 hours overhaul period recommended

Lubrication required ever

ears

MTBF 122,550 hours with 90% confidence at rated load with 2 Hz ± 2 mm

noise and annual maintenance includin

driver

Fail-safe Actuation Position to 0% on loss of demand si

nal

Normal Ambient Operating

Temperature –18 to +121 °C / 0 to +250 °F

Rated Ambient Operating

Temperature –40 to +121 °C / –40 to +250 °F

Stora

e Ambient Temperature

–

40 to +121 °C /

–

40 to +250 °F

Rated Operatin

Elevation 3000 m

(

10 000 ft.

)

max

IP Ratin

(

per IEC 60529

)

IP55

Vibrations (validation) Random vibration per Mil-STD 810F, M514.5 Category 22,

level/duration 2.3.11 Fi

ure 514.5C-16.

Vibrations (shock) US MIL-STD 810F, Method 516.5, Procedure 1. 10 G Peak, 11 ms

duration sawtooth pulse

Envelope and Mountin

See installation drawin

s and fi

ures below

Actuator Wei

ht 586 lbs

* Actuator output forces will be reduced below normal ambient operating temperature range due to increased grease

viscosity at cold temperatures.

** Dynamic performance can be influenced by the customer filter settings. Values assume additional customer

settings are turned off.

1Assumes slow modulation when following a base load. Does not consider additional power required as

seen in grid firming applications requiring continuous and fast ramping of power. If this is expected in the

application, please contact Woodward for additional information.

2Information provided for breaker and wire sizing. Input current required when performing a full 100%

step at the continuous application force.

Released

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