SIL Certified Large Electric Sonic Valve (LESV) Gas Fuel Control Valve

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Product Manual 26419

(Revision U, 2/2019)
Original Instructions
SIL Certified Large Electric Sonic Valve (LESV)

Gas Fuel Control Valve
2-inch, 3-inch, 4-inch, 6-inch
Installation and Operation Manual

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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.
General
Precautions Failure to follow instructions can cause personal injury and/or property damage.
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
Revisions 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 get the latest copy.
Any unauthorized modifications to or use of this equipment outside its specified

mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
Proper Use modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
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
Translated translation was made. Be sure to check manual 26455, Customer Publication
Publications 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 Out-of-date translations are marked with .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.
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 26419
Copyright © Woodward, Inc. 2015 - 2019
All Rights Reserved
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Manual 26419 LESV Gas Fuel Control Valve
Contents
WARNINGS AND NOTICES ............................................................................................................... 3

ELECTROSTATIC DISCHARGE AWARENESS...................................................................................... 4
REGULATORY COMPLIANCE ............................................................................................................ 5
CHAPTER 1. GENERAL INFORMATION .............................................................................................. 7
Introduction ................................................................................................................................................... 7
CHAPTER 2. DESCRIPTION ............................................................................................................ 27
Electrical Mechanical Actuator Assembly ................................................................................................... 27
Brushless DC Motor .................................................................................................................................... 27
Resolver Position Feedback Sensors ......................................................................................................... 27
Soft Stop Spring .......................................................................................................................................... 27
Valve ........................................................................................................................................................... 27
CHAPTER 3. INSTALLATION ........................................................................................................... 28
General........................................................................................................................................................ 28
Piping Installation ........................................................................................................................................ 30
Fuel Overboard Vent Connection ............................................................................................................... 30
Valve Characteristic Data............................................................................................................................ 31
Calibration ................................................................................................................................................... 31
Valve/Actuator Configuration Settings ........................................................................................................ 31
Electrical Connections................................................................................................................................. 34
CHAPTER 4. MAINTENANCE AND HARDWARE REPLACEMENT ......................................................... 41
Maintenance ................................................................................................................................................ 41
Hardware Replacement .............................................................................................................................. 41
Ball Screw Lubrication Procedure ............................................................................................................... 42
Bearing Lubrication Procedure ................................................................................................................... 44
Fuel Overboard Vent Port ........................................................................................................................... 45
CHAPTER 5. TROUBLESHOOTING .................................................................................................. 46
CHAPTER 6 SAFETY MANAGEMENT – SAFE POSITION FUEL SHUTOFF FUNCTION ........................... 48
Product Variations Certified ........................................................................................................................ 48
Covered LESV Versions ............................................................................................................................. 48
SFF (Safe Failure Fraction) for the LESV – Over Speed SIF ..................................................................... 48
Response Time Data .................................................................................................................................. 49
Limitations ................................................................................................................................................... 49
Management of Functional Safety .............................................................................................................. 49
Restrictions ................................................................................................................................................. 49
Competence of Personnel........................................................................................................................... 49
Operation and Maintenance Practice.......................................................................................................... 49
Installation and Site Acceptance Testing .................................................................................................... 49
Functional Testing after Initial Installation ................................................................................................... 49
Functional Testing after Changes ............................................................................................................... 50
Proof Test (Functional Test)........................................................................................................................ 50
Suggested Proof Test ................................................................................................................................. 50
Proof Test Coverage ................................................................................................................................... 50
CHAPTER 7. PRODUCT SUPPORT AND SERVICE OPTIONS .............................................................. 51
Product Support Options ............................................................................................................................. 51
Product Service Options ............................................................................................................................. 51
Returning Equipment for Repair ................................................................................................................. 52
Replacement Parts...................................................................................................................................... 53
Engineering Services .................................................................................................................................. 53
Contacting Woodward’s Support Organization ........................................................................................... 53
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Technical Assistance .................................................................................................................................. 54
REVISION HISTORY ....................................................................................................................... 55
DECLARATIONS ............................................................................................................................ 56
Illustrations and Tables
Figure 1-1a. Outline Drawing (2-Inch LESV Class 300) ............................................................................... 9

Figure 1-1b. Outline Drawing (2-Inch LESV Class 300) ............................................................................. 10
Figure 1-2a. Outline Drawing (2-Inch LESV Class 600) ............................................................................. 11
Figure 1-9. Representative Outline Deviation of High Recovery Valves .................................................... 25
Figure 1-10. Connector Pin-outs ................................................................................................................. 26
Figure 3-1. Illustration of Diverging Sleeve Screws .................................................................................... 28
Figure 3-2. Illustration of Raised Face Style Diverging Sleeve................................................................... 29
Figure 3-3. Illustration of Extension Style Diverging Sleeve ....................................................................... 29
Figure 3-4. Power Connector ...................................................................................................................... 35
Figure 3-5. Motor Resolver Connectors ...................................................................................................... 35
Figure 3-6. ID Module/Shaft Resolver Actuator Connector ........................................................................ 36
Figure 3-7. Cable, Motor Resolver 1, Feedback Signal .............................................................................. 37
Figure 3-8. Cable, Stem Shaft Resolver, Feedback Signal ........................................................................ 38
Figure 3-9. Cable, Motor Power .................................................................................................................. 39
Figure 3-10. Cable, Motor Resolver 2, Feedback Signal ............................................................................ 40
Table 1-1. LESV Large Electric Sonic Valve Specifications ......................................................................... 7

Table 1-2. Dimensions “L” and “D” per Figure 1-5 for High Recovery LESVs ............................................ 25
Table 1-3. Dimensions “L” and “D” per Figure 1-5 for Ultra High Recovery LESVs ................................... 25
Table 3-1. Piping Loads According to Valve Size ....................................................................................... 30
Table 3-2. Valve Part Number Specific Parameters ................................................................................... 32
Table 3-3. Valve Serial Number Specific Parameters ................................................................................ 33
Table 5-1. Troubleshooting Symptom, Cause, and Remedy ...................................................................... 46
Table 6-1. Failure Rates according to IEC61508 in FIT ............................................................................. 48
Table 6-2. Suggested Proof Test ................................................................................................................ 50
Table 6-3. Proof Test Coverage .................................................................................................................. 50
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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.
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,
Overspeed / loss of life, or property damage.
Overtemperature / The overspeed shutdown device must be totally independent of the
Overpressure prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
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
Personal Protective the job at hand. Equipment that should be considered includes but is
not limited to:
Equipment
 Eye Protection
 Hearing Protection
 Hard Hat
 Gloves
 Safety Boots
 Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
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
Start-up property damage.
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Electrostatic Discharge Awareness

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
Electrostatic the control turned off, contact a grounded surface and maintain
Precautions 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, the 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. Immediately after removing the old PCB from the control cabinet,
place it in the antistatic protective bag.
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Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking.
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)
Pressure Equipment Directive 2014/68/EU on the harmonisation of the laws of the Member
Directive: States relating to the making available on the market of pressure
equipment.
2-Inch, 3-Inch, 4-Inch: PED Category II
6-Inch: PED Category III
PED Module H – Full Quality Assurance,
CE-0041-PED-H-WDI 001-16-USA, Bureau Veritas UK Ltd (0041)
ATEX – Potentially Directive 2014/34/EU on the harmonisation of the laws of the Member
Explosive States relating to equipment and protective systems intended for use in
Atmospheres potentially explosive atmospheres.
Directive: Zone 2, Category 3, Group II G, Ex nA IIC T3 X Gc IP55
Other European Compliance:

Compliance with the following European Directives or standards does not qualify this product for
application of the CE Marking:
ATEX Exempt from the non-electrical portion of the ATEX Directive 2014/34/EU
due to no potential ignition sources per EN 13463-1.
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 (LELA Actuator): Certified for use in explosive atmospheres per Certificate IECEx CSA
14.0013X Ex nA IIC T3 Gc IP55
EAC Customs Union:

These listings are limited only to those units with labels, marking, and manuals in Russian language to
comply with their certificates and declaration.
EAC Customs Union Certified to Technical Regulation CU 012/2011 for use in potentially
(Marked): explosive atmospheres per Certificate RU С-US.ГБ08.B.01076 as
2Ex nA IIC T3 Gc X for electrical and II Gc TX for non-electrical portions of
the valve.
EAC Customs Union Certified to Technical Regulation CU 032/2013 On the safety of equipment
(Marked): operating under excessive pressure.
Certificate RU С-US.МЮ62.В.02208 for 6-inch valves.
EAC Customs Union: Declared to Technical Regulation CU 032/2013 On the safety of equipment
operating under excessive pressure.
Declaration of Conformity Registration No: RU Д-US.МЮ62.В.02150 for 2,
3, and 4-inch valves.
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EAC Customs Union Declared to Technical Regulation CU 010/2011 On the safety of machinery
and equipment. Declared to Technical Regulation CU 020/2011 On
Electromagnetic Compatibility of Technical Equipment. Declaration of
Conformity Registration No: RU Д-US.AƳ14.B.25099.
North American Compliance:

These listings are limited only to those units bearing the CSA Marking.
CSA (Actuator): CSA Certified for Class I, Division 2, Groups A, B, C, & D, T3 at 93 °C

Ambient For use in Canada and the United States Certificate 1635932
Actuator is certified for North America as on-engine systems component

connected to the certified Digital Valve Positioner.
SIL Compliance:
LESV – Certified SIL 3 Capable for safe position Fuel shutoff function in
safety instrumented systems. Evaluated to IEC 61508 Parts 1-7. Refer to
the instructions of this Installation and Operation Manual, Chapter 6 – Safety
Management – Safe Position Fuel Shutoff Function.
SIL Certificate WOO 1405126 C001
Link to Exida SIL 3 Certification
Special Conditions for Safe Use:

 Mating connectors must be installed to maintain IP55 rating.
 Connect the ground terminal to earth ground.
 Maximum ambient temperature 93 °C (200 °F).
 Use supply wires suitable for 10 °C (18 °F) above surrounding ambient.
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.
Wiring must be in accordance with North American Class I, Division 2, or European Zone 2, Category 3
wiring methods as applicable, and in accordance with the authority having jurisdiction.
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.
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
ou Zone 2.
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Chapter 1.
General Information
Introduction
The Large Electric Sonic Valve (LESV) controls the flow of gas fuel to the combustion system of an
industrial or utility gas turbine. The integral electric actuator consists of a brushless dc motor, resolver for
motor commutation and position sensing, valve stem resolver for motor resolver verification, fail-safe
spring for fail-safe operation, and a soft stop for fail-safe operations. The LESV utilizes a device (ID
Module) containing all the configuration and calibration information that is read by the Digital Valve
Positioner (DVP) when the valve/actuator is connected and powered up.
This valve is intended to operate only with a Woodward Digital Valve Positioner (DVP). Contact your
sales person for part numbers for your specific applications.
Table 1-1. LESV Large Electric Sonic Valve Specifications
Description 2, 3, 4, & 6-Inch (51, 76, 102, 152 mm) electrically actuated natural gas sonic
metering valve.
Mean Time Between 149 000 hrs. operation combined metering valve per valve/actuator/DVP/cable
Failure (MTBF) subsystem.
Ambient –40 to +93 °C (–40 to +200 °F)
Temperature Range
Approximate Class 300 LESV Class 600 LESV
Weights
2-Inch - 113 kg / 250 lb. 2-Inch – 113 kg / 250 lb.
ACTUATOR
Description Brushless dc motor with dual position feedback sensors.
Coil Class H insulation
Failure Mode Spring type to drive valve to safe position with loss of signal (Fail Close).
Bandwidth 35 rad/s with no more than 6 dB attenuation and less than 180 degrees phase
loss at ±2% magnitude and minimum supply voltage at DVP.
Visual Position Yes
Indication
Ingress Protection IP55
Characteristic High Recovery LESV Ultra-High Recovery LESV
Response Time 2-Inch—200 ms 2-Inch—400 ms
3-Inch—350 ms 3-Inch—700 ms
DVP Input Voltage 125 Vdc 220 Vdc
(typical)
DVP Input Voltage 150 Vdc 300 Vdc
(Max)
DVP Input Voltage 112.5 Vdc 112.5 Vdc
(min) (for full
dynamic
performance)
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VALVE
Operating Fluid Natural Gas
Gas Filtration 25 µm absolute at 75 beta requirement
Valve flange Class 300 Flange High Class 600 Flange High Class 600 Flange Ultra
connection Recovery LESV Recovery LESV High Recovery LESV
Min Fluid
–29 °C (–20 °F) –29 °C (–20 °F) –29 °C (–20 °F)
Temperature
Max Fluid
232 °C (450 °F) 260 °C (500 °F) 260 °C (500 °F)
Temperature
Min Fluid Pressure 0 kPa (0 psig) 0 kPa (0 psig) 0 kPa (0 psig)
Max Fluid Pressure 3902 kPa at 38 °C (566 4000 kPa at 38 °C (580 4171 kPa at 38 °C (605
psig at 100 °F) psig at 100 °F) psig at 100 °F)
3434 kPa at 232 °C (498 4000 kPa at 260 °C (580 4171 kPa at 260 °C (605
psig at 450 °F) psig at 500 °F) psig at 500 °F)
Proof Test Pressure/ 9480 kPa /
7584 kPa / 1100 psig 9136 kPa / 1325 psig
Production 1375 psig
Burst Pressure 5x maximum operating pressure.
Overboard Leakage <50 cm³/min as shipped (see Fuel Overboard Vent Port section).
Trim Sizes Contact Woodward for various Cg trim sizes.
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Figure 1-1a. Outline Drawing (2-Inch LESV Class 300)
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Figure 1-1b. Outline Drawing (2-Inch LESV Class 300)
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In the event the valves supplied are considered High Recovery, the following feature (extension) is added
in addition to the outline drawing dimensions for the outlet flange. Take care not to damage the extension.
Do NOT use the extension to support the valve in any manner.
Figure 1-9. Representative Outline Deviation of High Recovery Valves
Table 1-2. Dimensions “L” and “D” per Figure 1-5 for High Recovery LESVs
Valve Size Dimension “L” Dimension Recovery

(Inches) “D” (Inches) Factor
2-Inch 1.500 1.670 1.08
3-Inch 3.700 2.620 1.08
4-Inch 5.000 3.250 1.08
6-Inch 7.000 4.500 1.08
Table 1-3. Dimensions “L” and “D” per Figure 1-5 for Ultra High Recovery LESVs
Valve Size Dimension “L” Dimension Recovery

(Inches) “D” (Inches) Factor
2-Inch 4.000 1.880 1.06
3-Inch 6.000 2.810 1.06
4-Inch 8.000 3.960 1.06
6-Inch 12.000 5.580 1.06
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Figure 1-10. Connector Pin-outs
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Chapter 2.
Description
Electrical Mechanical Actuator Assembly

The electrical-mechanical actuator consists of a brushless dc motor that provides torque, an integral
resolver for motor commutation and position feedback to the controller, a valve stem resolver for motor
resolver verification, and a high-efficiency ball screw for rotary-to-linear motion conversion. The actuator
also contains a fail-safe spring designed to extend the actuator if power is removed from the actuator.
 A soft-stop spring to dissipate motor rotor inertia during fail-safe shutdown and prevent ball screw
damage
 A cam follower to provide apposing torque during slew operations
 A lifting eye to aid installation
Brushless DC Motor
The motor used on the LESV is a permanent magnet, electrically commutated, brushless dc motor. The
components used in the motor are rated for service from –40 to +155 °C (–40 to +311 °F). The motor is a
permanently lubricated assembly with a sealed enclosure rating of IP55.
Resolver Position Feedback Sensors

The primary position feedback transducer is the resolver that is integral to the dc brushless motor. The
actuator also has a valve stem resolver. This resolver is used as a watchdog function of the primary motor
control, to prevent runaway conditions and to ensure that the primary motor resolver is reading correctly.
Linear shaft motion is converted to angular rotation for the valve stem resolver through a linkage.
Parameter files are loaded onto the DVP to specifically match the valve characteristics in order to obtain
the most accurate position sensing.
Soft Stop Spring

Integral to the actuator is a soft stop spring. This provides a bumper like action if the actuator is driven
hard into the fully extended position. This will occur only on loss of power, certain wiring faults, and in rare
cases, internal fault conditions within the positioner. The soft stop mechanism is not used when the
positioner is controlling the actuator. Although the positioner will rapidly drive the actuator towards the
minimum position, it also decelerates the actuator as the actuator approaches the mechanical minimum
stop. Under the control of the positioner, the actuator should not reach the mechanical minimum stop at a
high velocity.
Valve
The SonicFlo contoured plug valve consists of a valve housing, metering plug, diverging sleeve, pilot
sleeve/bonnet, and actuator adapter. The metering elements of this valve are a contoured plug and a
hardened seat. The plug is contoured to provide various Cg versus position flow characteristics from 0%
to 100% stroke. Please contact Woodward for available trim sizes and Cg profiles.
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Chapter 3.
Installation
General
See the outline drawings (Figures 1-1 through 1-4) for:
 Overall dimensions
 Process piping flange locations
 Electrical connections
 Lift points and center of gravity
Installation attitude does not affect actuator or fuel valve performance, but a vertical position is generally
preferred to conserve floor space as well as ease of making electrical and fuel connections. The LESV is
designed for support by the piping flanges alone; additional supports are neither needed nor
recommended. Do not use this valve to provide support to any other component in the system. The piping
should be aligned and adequately supported such that excessive piping loads are not transmitted to the
valve body.
EXPLOSION HAZARD—The surface temperature of this valve

approaches the maximum temperature of the applied process media.
It is the responsibility of the user to ensure that the external
environment contains no hazardous gases capable of ignition in the
range of the process media temperatures.
Do not operate the valve without proper support for the diverging
sleeve. IF BENCH TESTING THE VALVE, ENSURE THAT ASME/ANSI
RATED FLANGES ARE GASKETED AND INSTALLED OVER THE
INLET AND DISCHARGE FLANGES WITH THE BOLTS PROPERLY
TORQUED. The diverging sleeve screws by themselves are not
designed to hold pressure loads. Failure to comply with this warning
may result in personal injury. Do not place hands inside valve body
during inspection, cleaning, or operation.
Figure 3-1. Illustration of Diverging Sleeve Screws
Diverging Sleeve assembly screws are not designed to hold pressure loads. If bench testing, do not
apply pressure to the valve without ANSI flanges (see below figures).
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Figure 3-2. Illustration of Raised Face Style Diverging Sleeve
Raised Face style diverging sleeves should be secured with a blind flange when bench testing
Figure 3-3. Illustration of Extension Style Diverging Sleeve
Extension style diverging sleeves should be secured with a threaded or weld neck style flange when
bench testing.
Due to typical noise levels in turbine environments, hearing

protection should be worn when working on or around the Large
Electric Sonic Valve. Noise levels of greater than 90 dB are possible.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
Lift or handle the valve only by using the eyebolts.
The LESV is not designed to be a step or to support the weight of a

person.
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External fire protection is not provided in the scope of this product. It

is the responsibility of the user to satisfy any applicable
requirements for their system.
Piping Installation
Refer to ANSI B16.5 for details of flange, gasket, and bolt types and dimensions. Verify that the process
piping face-to-face dimensions meet the requirements of the outline drawings (Figures 1-1 through 1-4)
within standard piping tolerances. The valve should mount between the piping interfaces such that the
flange bolts can be installed with only manual pressure applied to align the flanges. Mechanical devices
such as hydraulic or mechanical jacks, pulleys, chain-falls, or similar equipment should never be used to
force the piping system to align with the valve flanges.
ASTM/ASME grade bolts or studs should be used to install the valve into the process piping. The length
and diameter of the bolts and studs shall conform to ANSI B16.5 according to the valve flange size and
class.
Flange gasket materials should conform to ANSI B16.20. The user should select a gasket material which
will withstand the expected bolt loading without injurious crushing, and which is suitable for the service
conditions.
When installing the valve into the process piping, it is important to properly torque the studs/bolts in the
appropriate sequence in order to keep the flanges of the mating hardware parallel to each other. A two-
step torque method is recommended. Once the studs/bolts are hand-tightened, torque the studs/bolts in a
crossing pattern to half the required torque. Once all studs/bolts have been torqued to half the appropriate
value, repeat the pattern until the rated torque value is obtained.
Do not insulate the valve or actuator. Insulation may be used on the inlet horizontal leg of the pipe. There
should be no insulation around the outlet flange of the valve or the outlet riser pipe. If the outlet riser pipe
is longer than 6 diameters, insulation may be used below the 6-diameter mark. This is because the purge
temperature is extremely hot and may damage the valve seals.
Note: The Valve discharge flange must not exceed 277°C (530°F) when the valve is closed and the
downstream circuit is being purged.
Piping loads that can be considered “typical” have been used in the design of the housing to ensure that
there is not an adverse effect from the stresses applied to the housing from the inlet and outlet piping.
The loads which were used in the design of these housings are (and should not be exceeded):
Table 3-1. Piping Loads According to Valve Size
Valve Size Max Axial Pipe Force Max Pipe Moment

50 mm 3600 N 2200 N·m
(2 inch) (809.3 lbs.) (1622.6 lb-ft)
80 mm 5400 N 3300 N·m
(3 inch) (1214 lbs.) (2434 lb-ft)
100 mm 7200 N 4400 N·m
(4 inch) (1618 Lbs) (3245.3 lb-ft)
150 mm 110000 N 6600 N·m
(6 inch) (2472.9 lbs) (4867.9 lb-ft)
Fuel Overboard Vent Connection

There is a fuel overboard vent port that must be vented to a safe location. In normal operation, this vent
should have very low leakage.
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Never plug the fuel overboard vent port, which could cause the valve
to malfunction or to operate improperly.
Valve Characteristic Data

Flow testing is conducted on every valve before shipment. Results from this flow testing produce Cg
versus position characteristics of the valve. Each valve must demonstrate predetermined Cg
characteristics before it can be shipped.
Calibration
The actuator and controller perform an automatic rigging procedure. When the actuator controller is
activated, it performs an automatic rigging procedure that checks system health and verifies the value is
in the proper position. No additional steps are required from the operator.
Valve/Actuator Configuration Settings

The LESV utilizes a device (ID Module) containing all the configuration and calibration information that is
read by the Digital Valve Positioner (DVP) when the valve/actuator is connected and powered up. Initial
configuration settings for the valve/actuator do not need to be entered into the DVP due to the ID Module
communicating directly with the positioner. However, in the unlikely event the configuration settings must
be entered manually, the following tables outline the necessary configuration settings for the LESV.
These configuration settings are broken up into three groups: User Configuration Parameters, Valve Part
Number Specific Parameters, and Valve Serial Number Specific Parameters. Some of the configuration
settings include factory calibration information. Please contact Woodward with the valve part number and
serial number for the data containing the specific calibration and configuration settings if the need arises.
Many of these parameters are accessible via the Woodward Service Tool.
User Configuration Parameters

The User Configuration Parameters are used in the DVP to define the interface between the DVP and the
turbine control system. Examples of these include the demand type selection, analog input scaling,
discrete input and output configurations, etc. For a complete description of all the options for the User
Configuration Parameters, please see the DVP product manual.
Valve Part Number Specific Parameters

These parameters define the settings based on a particular valve type (part number). Every valve of the
same type, regardless of serial number, will have the same settings. Please refer to the table below for a
definition of these settings. For instructions on how to enter these values, please refer to the DVP
manual.
Please contact Woodward for the correct settings for your application.
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Table 3-2. Valve Part Number Specific Parameters
Parameter Name Description Value/Units

ValveTypeId.
IdModuleVersion Parameter set version 1 = Rev 0
2 = Rev 1, etc.
ValveType Selects valve type 9 = 1.5” Stroke LESV
10 = 3.0” Stroke LESV
11 = 0.5” Stroke LESV
ValveProductCode Upper level part number of valve xxxx-xxxx
assembly
ValveProductRev EC Revision of Valve Assembly 1 = NEW
2=A
3 = B, etc.
100 = Rev 0
101 = Rev 1, etc.
BLDCPosStateParams.
MinCheckCurrent Current to close valve during min amps
startup check
MaxCheckCurrent Current to preload valve in opening amps
direction during min startup check
MotorDirectioncheckLimit Min movement in the closing % of electrical revolution
direction during startup check to
avoid a motor direction error
SetPosZeroCutOffParams.
Mode Turns on or off the zero cut off 0 = Off
function 1 = On
LowLimit Zero cut off will be turned on below %
this stroke
HighLimit Zero cut off will be turned off above %
this limit
DelayTime Delay time before zero cut off is ms
turned on
ModelPositionErrParams.
PosErrMotorAlarmTime Motor resolver delay time before a sec
position error is flagged as an alarm
PosErrMotorAlarmLimit Alarm limit for error allowed %
between the position demand and
the motor resolver feedback
PosErrMotorShutdownTime Motor resolver delay time before a sec
position error creates a shutdown
PosErrMotorShutdownLimit Shutdown limit for error allowed %
the motor resolver feedback
PosErrShaftAlarmTime Shaft resolver delay time before a sec
position error is flagged as an alarm
PosErrShaftAlarmLimit Alarm limit for error allowed %
the shaft resolver feedback
PosErrShaftShutdownTime Shaft resolver delay time before a sec
position error creates a shutdown
PosErrShaftShutdownLimit Shutdown limit for error allowed %
the shaft resolver feedback
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Parameter Name Description Value/Units

NoiseFilterParams.
NoiseFilterMode Selects noise filter mode
Bandwidth Input noise filter bandwidth Hz
Damping Input noise filter damping Typical 2nd order response is 1.0
Threshold Below this threshold the gain %
setting will be used, above this
threshold the gain setting will be
set to 1.0
Gain
PaceMakerParams.
Mode Turns on or off the pace maker 0 = Off
function 1 = On
DelayTime Delay time between pace maker min
pulses
PositionStep Position demand magnitude for %
the pace maker pulse
ImpulseHalfDuration Time pulse remains high, also ms
time pulse remains low
Valve Serial Number Specific Parameters

Each valve, regardless of valve type or part number, will have a set of unique settings corresponding to
the calibration process done on each unit at the factory. Refer to the table below for a definition of these
settings. Please contact Woodward in the event these values need to be entered into the DVP.
Table 3-3. Valve Serial Number Specific Parameters
Parameter Name Description Value

ValveTypeId.
ValveSerialNum Valve assembly serial number Factory Calibrated
ResolverScalingParms.
Shaft1Resolver.LelaScaling.Length1 Secondary resolver calibration Factory Calibrated
Shaft1Resolver.LelaScaling.Length2 Secondary resolver calibration Factory Calibrated
Shaft1Resolver.LelaScaling.Xoffset Secondary resolver calibration Factory Calibrated
Shaft1Resolver.LelaScaling.YatZero Secondary resolver calibration Factory Calibrated
Shaft1Resolver.LelaScaling.YatMax Secondary resolver calibration Factory Calibrated
Shaft1Resolver.LelaScaling.ROffset Secondary resolver calibration Factory Calibrated
Shaft1Resolver.LelaScaling.RRollOv Secondary resolver calibration Factory Calibrated
er
BLDCPosStateParams.
MinCheckMotorResMin Startup diagnostic limit Factory Calibrated
MinCheckMotorResMax Startup diagnostic limit Factory Calibrated
MinCheckShaftResMin Startup diagnostic limit Factory Calibrated
MinCheckShaftResMax Startup diagnostic limit Factory Calibrated
MaxCheckMotorResMin Startup diagnostic limit Factory Calibrated
MaxCheckMotorResMax Startup diagnostic limit Factory Calibrated
MaxCheckShaftResMin Startup diagnostic limit Factory Calibrated
MaxCheckShaftResMax Startup diagnostic limit Factory Calibrated
MotorResolverOffset Startup diagnostic limit Factory Calibrated
SetPosOffsetParams.Offset Calibration position offset Factory Calibrated
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Electrical Connections
Due to the hazardous location listings associated with this product,

proper wire type and wiring practices are critical to operation.
Do not connect any cable grounds to “instrument ground”, “control

ground”, or any non-earth ground system. Make all required
electrical connections based on the wiring diagrams (Figure 1-6).
This product is designed for use with three (or four with optional redundant motor resolver) dedicated
cables that connect the Digital Valve Positioner to the LESV assembly. These cables must be used for
the system to meet all CSA, ATEX, EMC, and LVD requirements. Please contact Woodward for the
appropriate cable configuration.
Refer to the outline drawings (Figures 1-1 through 1-4) for location of grounding lug in order to properly
earth ground the LESV.
Figures 3-7, 3-8, 3-9, and 3-10 show drawings typical of the four dedicated cables used to connect the
LESV valve to the DVP driver. The drawings in these figures include wiring diagrams and connector
descriptions. Application specific requirements such as termination at the DVP, length and environmental
conditions, etc., may result in a custom implementation of these cables by the customer.
Electrical circular connectors must be properly seated and

tightened in order to provide correct performance, to eliminate
potential shock hazard, and to maintain the LESV’s IP rating.
Connect external ground terminal of actuator to the earth ground. This must be the same grounding
system as the driver’s earth ground.
The LESV are to be used only with the Woodward Digital Valve
Positioner (DVP).
Wiring must be in accordance with North American Class I, Division

2 or International Zone 2 wiring methods as applicable and in
accordance with the authority having jurisdiction.
Firmly seat all electrical connections on the appropriate connector. A seating torque of 22 inch pounds
(2.5 N*m) should be applied to the power connector to ensure proper connection.
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Power Connector
The mating power cable connector shall be installed hand-tight followed by a final torque of 2.5 Nm (22
lb.-in) to meet the IP rating.
Figure 3-4. Power Connector
Note: Actual connector orientation on motor may appear different than that shown.
Motor Resolver Connectors (Two Resolvers)

Install these two mating cable connectors by hand, so that the red line is no longer visible and the
connector cannot be turned any further.
Figure 3-5. Motor Resolver Connectors
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ID Module/Shaft Resolver Actuator Connector

Install the mating cable connector by hand, so that the red line is no longer visible and the connector
cannot be turned any further.
Figure 3-6. ID Module/Shaft Resolver Actuator Connector
Note: Actual connector location on actuator may appear different than that shown.
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Figure 3-7. Cable, Motor Resolver 1, Feedback Signal
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Figure 3-8. Cable, Stem Shaft Resolver, Feedback Signal
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Figure 3-9. Cable, Motor Power
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Figure 3-10. Cable, Motor Resolver 2, Feedback Signal
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Chapter 4.
Maintenance and Hardware Replacement
Maintenance
The only maintenance required for the Large Electric Sonic Valve is lubricating the ball screw and bearing
and inspecting the fuel overboard vent port every 12 months, in accordance with the descriptions below.
The LESV is not designed with field-replaceable components. Contact the turbine manufacturer (primary
contact) or Woodward (secondary contact) for assistance in the event there is a problem requiring service
or replacement.
Hardware Replacement
EXPLOSION HAZARD—Substitution of components may impair

suitability for Class I, Division 2 or Zone 2.
To prevent possible serious personal injury, or damage to equipment,

be sure all electric power, hydraulic pressure, and gas pressure have
been removed from the valve and actuator before beginning any
maintenance or repairs.
Lift or handle the valve only by using the eyebolts.
Due to typical noise levels in turbine environments, hearing

protection should be worn when working on or around the Large
Electric Sonic Valve. Noise levels of greater than 90 dB are possible.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
The LESV contains a mechanical spring under load. Do not

disassemble, as this spring can cause bodily harm.
Use only Woodward-approved grease to lubricate the ball screw and

bearing in this actuator. Use of any other grease will reduce
performance and reliability. Woodward lubrication kits are available
as part number 8923-1186.
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Ball Screw Lubrication Procedure
Wear rubber gloves in order to avoid contact with the grease

during the lubrication procedure.
Lubricating the Ball Screw Assembly

1. Clean the outside of the actuator to ensure that no debris gets inside the actuator during the
lubrication process. Any debris on the ball screw will reduce its life.
2. Remove the ball screw access plug located on the top of the gear cover with a 5/16 inch hex wrench
(Figure 4-1).
3. Remove the ball screw port plug with a 3/16 inch hex wrench (Figure 4-2).
4. Set the ball screw access and port plugs aside and keep clean, ensuring that they are not scratched
or marred.
5. Attach the thread connector of the grease syringe to the threaded grease port of the ball screw. The
fitting should be fully seated (Figure 4-3).
6. Inject 2 cm³ of Woodward approved grease (8923-1186) into the ball screw grease port.
7. Remove the grease syringe from the ball screw grease port and install the ball screw port plug. Do
not torque the port plug (Figure 4-4).
8. Remove the plug that is adjacent to the ball screw port, set aside, and keep clean, ensuring that the
plug is not scratched or marred (Figure 4-5).
9. Using a permanent marker or tape, mark a 5/32 inch Allen wrench at 2.75 inches from the bottom.
Make sure the top of the marking is at 2.75 inches (Figure 4-6).
10. Insert the Allen wrench into the port located adjacent to the ball screw port. The Allen wrench is
seated if the marking is below the top surface of the gear cover (Figure 4-7).
11. If the Allen wrench is not seated, rotate the gears using a 3/16 inch hex wrench on the ball screw port
plug and rotate clockwise until the 5/32 inch Allen wrench is seated.
12. Once the 5/32 inch Allen wrench is seated, torque the ball screw port plug to 38–42 lb.-in (4.3–4.7
Nm) (Figure 4-8).
13. Remove the 5/32 inch Allen wrench from the port, install the plug into the port located adjacent to the
ball screw port, and torque to 38–42 lb.-in
(4.3–4.7 Nm) (Figure 4-9).
14. Install the ball screw access plug and torque to 145–155 lb.-in
(16.4–17.5 Nm) (Figure 4-10).
Figure 4-1 Figure 4-2
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Bearing Lubrication Procedure

Lubricating the Bearing Assembly
1. Clean the outside of the actuator to ensure that no debris gets inside the actuator during the
lubrication process. Any debris in the bearing will reduce its life.
2. Remove the bearing port plug with a 3/16 inch hex wrench (Figure 4-11).
Note: Some actuator models have bearing port plugs on both sides of the gearbox housing to allow
for access from either side. For these models, the following greasing procedure only needs to be
performed on one grease port. Leave the plug installed in the other port that is not being greased.
3. Set the plug aside and keep clean, ensuring that the inside plug surface is not scratched or marred.
4. Attach the thread connector of the grease syringe to the threaded bearing grease port. The fitting
should be fully seated (Figure 4-12).
5. Inject 2 cm³ of Woodward approved grease (8923-1186) into the bearing grease port.
6. Remove the grease syringe from the bearing port and install the bearing port plug. Torque to 38–42
lb.-in (4.3–4.7 Nm) (Figure 4-13).
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Figure 4-13
Fuel Overboard Vent Port

There is a fuel overboard vent port that must be vented to a safe location. In normal operation, this vent
should have very low leakage. However, if excessive leakage is detected from this vent port, contact a
Woodward representative for assistance.
Never plug the fuel overboard vent port, which could cause the valve
to malfunction or to operate improperly.
Fuel Overboard Vent Port Annual Inspections

Pressurize the valve section of the assembly to the rated pressure of
3447 kPa (500 psig) and perform the following inspections:
 Inspect external sealing surfaces for leakage using leak detect fluid (no leakage is permitted). These
locations include the inlet and discharge flange connections, as well as the pilot sleeve/valve body
interface.
 Inspect for excessive overboard vent leakage (100 cm³/min maximum / 6.1 in³/min) from the Fuel
Overboard Vent Port.
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Chapter 5.
Troubleshooting
Faults in the fuel control or governing system are often associated with speed variations of the prime
mover, but such speed variations do not always indicate fuel control or governing system faults.
Therefore, when improper speed variations occur, check all components, including the engine or turbine,
for proper operation. Refer to the applicable electronic control manuals for assistance in isolating the
trouble. The following steps describe troubleshooting for the gas fuel control valve.
Disassembly of the Large Electric Sonic Valve in the field is not recommended due to the dangerous
forces contained in the springs. Under unusual circumstances, where disassembly becomes necessary,
all work and adjustments should be made by personnel thoroughly trained in the proper procedures.
When inspecting the valve for suspected blockages, remove the valve from the fuel system and only
inspect with the unit powered off.
The LESV contains a mechanical spring under load. Do not

disassemble, as this spring can cause bodily harm.
When inspecting the valve internally through the flanges for potential
blockages, remove the valve from the fuel system and ensure that all
power and electrical cables are disconnected. Never place hands
inside the valve without ensuring that power is disconnected and the
position indicator shows the valve is at the closed position.
Do not operate the valve without proper support for the diverging
sleeve. The diverging sleeve can only be properly supported by
bolting and by properly torqueing the outlet flange to either piping or
an equivalent flange. Do not place hands inside the valve body
during inspection, cleaning, or operation.
Note: When requesting information or service help from Woodward, it is important to include the part
number and serial number of the valve assembly in your communication.
Table 5-1. Troubleshooting Symptom, Cause, and Remedy
Symptom Possible Causes Remedies

Valve will not Motor wires not properly connected between DVP and Conduct continuity check.
open because actuator
the DVP will not Resolver wires not properly connected between DVP Conduct continuity check.
reset and actuator
DVP will reset Resolver sine wires high and low are flipped Conduct continuity check.
but valve will Resolver cosine wires high and low are flipped Conduct continuity check.
not open Resolver sine and cosine wires are swapped Conduct continuity check.
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Symptom Possible Causes Remedies

Upon enabling, Resolver sine and cosine wires are swapped, and sine Conduct continuity check.
valve will open wires high and low are flipped
and then fail Resolver sine and cosine wires are swapped, and Conduct continuity check.
closed cosine wires high and low are flipped
Poor flow Characterization data in engine control does not Verify characterization
accuracy match the valve data matches the valve
serial number.
Build-up of contamination on the seat Remove valve and
inspect flow elements.
Poor position One motor wire disconnected Conduct continuity check.
stability
Valve stem Incorrect parameter file loaded Verify the parameter file
resolver matches the valve serial
indicates number.
position error Valve stem resolver wires not properly connected Contact manufacture for
between DVP and actuator instructions or return to
manufacturer for repair.
Faulty resolver Return to manufacturer
for repair.
Drive train failure Return to manufacturer
for repair.
High overboard Internal seals damaged Return to manufacturer
vent leakage for repair.
High seat Damage to valve seat or plug Remove valve and
leakage inspect flow elements.
Return to manufacturer
for repair.
Contamination buildup in seat or plug Remove valve and
inspect flow elements.
Return to manufacturer
for repair.
Valve not fully closed Remove valve and verify
plug is not properly
seated. Return to
manufacturer for repair.
External gas Piping flange gaskets missing or deteriorated Replace gaskets.
fuel leakage Piping flanges improperly aligned Rework piping as needed
to achieve alignment
requirements detailed in
Chapter 3.
Piping flange bolts improperly torqued Rework bolts as needed
to achieve torque
requirements detailed in
Chapter 3.
Packing missing or deteriorated Return actuator to
Woodward for service.
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Chapter 6
Safety Management – Safe Position Fuel Shutoff
Function
Product Variations Certified

The SIL rated LESV for fuel shutoff is designed and certified to the functional safety standards according
to IEC61508, Parts 1 through 7. Reference the product FMEDA: WOO 10-11-064 R001 V1R3, and
Certification: WOO 1405129 C001.
The functional safety requirement in this chapter applies to all LESVs. The SIL rated LESVs will have a
DU FIT of less than 953 FITS for Close to Trip Full Stroke.
The LESV is certified for use in applications up to SIL 3 according to IEC61508.
The LESV is designed and verified to withstand the worst-case (or greater) expected environmental
conditions as listed in other sections of this manual.
Covered LESV Versions

All LESVs are SIL certified for the shutoff function.
SFF (Safe Failure Fraction) for the LESV – Over Speed SIF
The LESV is only one part of a shutoff system that supports an over-speed shutdown SIF (Safety
Instrumented Function). This system consists of a speed sensor, a processing unit and a fuel shutoff
actuation sub-system of which the LESV is a component.
The SFF (Safe Failure Fraction) for each subsystem should be calculated. The SFF summarizes the
fraction of failures which lead to a safe state plus the fraction of failures which will be detected by
diagnostic measures and lead to a defined safety action. This is reflected in the following formulas for
SFF:
SFF = λSD + λSU + λDD / λTOTAL
Where λTOTAL = λSD + λSU + λDD + λDU
The failure rates listed below, for only the LESV, do not include failures due to wear-out of any
components. They reflect random failures and include failures due to external events such as unexpected
use. Reference the FMEDA: WOO 10-11-064 R001 V1R3 for detailed information concerning the SFF
and PDF.
Table 6-1. Failure Rates according to IEC61508 in FIT
Device λSD λSU λDD λDU

Full Stroke 0 136 0 953
Full Stroke with PVST 136 0 343 610
According to IEC 61508 the architectural constraints of an element must be determined. This can be done
by following the 1H approach according to 7.4.4.2 of IEC 61508 or the 2H approach according to 7.4.4.3
of IEC 61508. The 1H approach should be used for the LESV.
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Response Time Data

The LESV full stroke response time is 1 second maximum from 100% position to fully close.
Limitations
When proper installation, maintenance, proof testing, and environmental limitations are observed, the
useful life of the LESV is 15 years. The LESV can be refurbished and a product life of 30 years can be
achieved.
Management of Functional Safety

The LESV is intended for use according to the requirements of a safety lifecycle management process
such as IEC61508 or IEC61511. The safety performance numbers in this chapter can be used for the
evaluation of the overall safety lifecycle.
Restrictions
The user must complete a full functional check of the LESV after initial installation, and after any
modification of the overall safety system. No modification shall be made to the LESV unless directed by
Woodward. This functional check should include as much of the safety system as possible, such as
sensors, transmitters, actuators, and trip blocks. The results of any functional check shall be recorded for
future review.
The LESV must be used within the published specification in this manual.
Competence of Personnel
All personnel involved in the installation and maintenance of the LESV must have appropriate training.
Training and guidance materials are included in this manual.
These personnel shall report back to Woodward any failures detected during operation that may impact
functional safety.
Operation and Maintenance Practice

A periodic proof (functional) test of the LESV is required to verify that any dangerous faults not detected
by safety controller internal run-time diagnostics are detected. More information is in the “Proof Test”
section below. The frequency of the proof test is determined by the overall safety system design, of which
the LESV is part of the safety system. The safety numbers are given in the following sections to help the
system integrator determine the appropriate test interval.
The LESV requires no special tools for operation or maintenance of the LESV.
Installation and Site Acceptance Testing

Installation and use of the LESV must conform to the guidelines and restrictions included in this manual.
No other information is needed for installation, programming, and maintenance.
Functional Testing after Initial Installation

A functional test of the LESV is required prior to use in a safety system. This should be done as part of
the overall safety system installation check and should include all I/O interfaces to and from the LESV.
For guidance on the functional test, see the Proof Test procedure below.
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Functional Testing after Changes

A functional test of the LESV is required after making any changes that affect the safety system. Although
there are functions in the LESV that are not directly safety related, it is recommended that a functional
test be performed after any change.
Proof Test (Functional Test)

The LESV must be periodically proof tested to ensure there are no dangerous faults present that are not
detected by on-line diagnostics. This proof test should be performed at least once per year.
Suggested Proof Test

The suggested proof test consists of a full stroke of the valve, shown in the table below.
Table 6-2. Suggested Proof Test
Step Action
1. Bypass the safety function and take appropriate action to avoid a false trip.
2. Interrupt or change the signal/supply to the actuator to force the actuator and valve to the Fail-
Safe state and confirm that the Safe State was achieved and within the correct time.
3. Re-store the supply/signal to the actuator and inspect for any visible damage or contamination
and confirm that the normal operating state was achieved.
4. Inspect the valve for any leaks, visible damage or contamination.
5. Remove the bypass and otherwise restore normal operation.
For the test to be effective the movement of the valve must be confirmed. To confirm the effectiveness of
the test both the travel of the valve and slew rate must be monitored and compared to expected results to
validate the testing.
Proof Test Coverage

The Proof Test Coverage for the LESV is given in the table below.
Table 6-3. Proof Test Coverage
Application Safety Function λDUPT6 Proof Test Coverage

No PVST with PVST
Clean Service Close on Trip – Full Stroke 394 59% 35%
The suggested proof test and proof test coverage is referenced in the product FMEDA; WOO Q10-11-064
R001 V1R3.
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Chapter 7.
Product Support and Service Options
Product Support Options

If you are experiencing problems with the installation, or unsatisfactory performance of a Woodward
product, the following options are available:
 Consult the troubleshooting guide in the manual.
 Contact the manufacturer or packager of your system.
 Contact the Woodward Full Service Distributor serving your area.
 Contact Woodward technical assistance (see “How to Contact Woodward” later in this chapter) and
discuss your problem. In many cases, your problem can be resolved over the phone. If not, you can
select which course of action to pursue based on the available services listed in this chapter.
OEM or Packager Support: Many Woodward controls and control devices are installed into the equipment
system and programmed by an Original Equipment Manufacturer (OEM) or Equipment Packager at their
factory. In some cases, the programming is password-protected by the OEM or packager, and they are the
best source for product service and support. Warranty service for Woodward products shipped with an
equipment system should also be handled through the OEM or Packager. Please review your equipment
system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a global network of
independent business partners whose mission is to serve the users of Woodward controls, as described
here:
 A Full Service Distributor has the primary responsibility for sales, service, system integration
solutions, technical desk support, and aftermarket marketing of standard Woodward products within
a specific geographic area and market segment.
 An Authorized Independent Service Facility (AISF) provides authorized service that includes repairs,
repair parts, and warranty service on Woodward's behalf. Service (not new unit sales) is an AISF's
primary mission.
 A Recognized Turbine Retrofitter (RTR) is an independent company that does both steam and gas
turbine control retrofits and upgrades globally, and can provide the full line of Woodward systems
and components for the retrofits and overhauls, long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available at www.woodward.com/directory.
Product Service Options

The following factory options for servicing Woodward products are available through your local Full-
Service Distributor or the OEM or Packager of the equipment system, based on the standard Woodward
Product and Service Warranty (5-01-1205) that is in effect at the time the product is originally shipped
from Woodward or a service is performed:
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 Flat Rate Remanufacture
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Replacement/Exchange: Replacement/Exchange is a premium program designed for the user who is in
need of immediate service. It allows you to request and receive a like-new replacement unit in minimum
time (usually within 24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime. This is a flat-rate program and includes the full standard
Woodward product warranty (Woodward Product and Service Warranty 5-01-1205).
This option allows you to call your Full-Service Distributor in the event of an unexpected outage, or in
advance of a scheduled outage, to request a replacement control unit. If the unit is available at the time of
the call, it can usually be shipped out within 24 hours. You replace your field control unit with the like-new
replacement and return the field unit to the Full-Service Distributor.
Charges for the Replacement/Exchange service are based on a flat rate plus shipping expenses. You are
invoiced the flat rate replacement/exchange charge plus a core charge at the time the replacement unit is
shipped. If the core (field unit) is returned within 60 days, a credit for the core charge will be issued.
Flat Rate Repair: Flat Rate Repair is available for the majority of standard products in the field. This
program offers you repair service for your products with the advantage of knowing in advance what the
cost will be. All repair work carries the standard Woodward service warranty (Woodward Product and
Service Warranty 5-01-1205) on replaced parts and labor.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat Rate Repair option with
the exception that the unit will be returned to you in “like-new” condition and carry with it the full standard
Woodward product warranty (Woodward Product and Service Warranty 5-01-1205). This option is
applicable to mechanical products only.
Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair, please contact your Full-
Service Distributor in advance to obtain Return Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:
 Return authorization number
 Name and location where the control is installed
 Name and phone number of contact person
 Complete Woodward part number(s) and serial number(s)
 Description of the problem
 Instructions describing the desired type of repair
Packing a Control
Use the following materials when returning a complete control:
 Protective caps on any connectors
 Antistatic protective bags on all electronic modules
 Packing materials that will not damage the surface of the unit
 At least 100 mm (4 inches) of tightly packed, industry-approved packing material
 A packing carton with double walls
 A strong tape around the outside of the carton for increased strength
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.
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Replacement Parts
When ordering replacement parts for controls, include the following information:
 The part number(s) (XXXX-XXXX) that is on the enclosure nameplate
 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
 Product Training
 Field Service
Technical Support is available from your equipment system supplier, your local Full-Service Distributor, or
from many of Woodward’s worldwide locations, depending upon the product and application. This service can
assist you with technical questions or problem solving during the normal business hours of the Woodward
location you contact. Emergency assistance is also available during non-business hours by phoning
Woodward and stating the urgency of your problem.
Product Training is available as standard classes at many of our worldwide locations. We also offer
customized classes, which can be tailored to your needs and can be held at one of our locations or at
your site. This training, conducted by experienced personnel, will assure that you will be able to maintain
system reliability and availability.
Field Service engineering on-site support is available, depending on the product and location, from many
of our worldwide locations or from one of our Full-Service Distributors. The field engineers are
experienced both on Woodward products as well as on much of the non-Woodward equipment with which
our products interface.
For information on these services, please contact us via telephone, email us, or use our website:
www.woodward.com.
Contacting Woodward’s Support Organization

For the name of your nearest Woodward Full-Service Distributor or service facility, please consult our
worldwide directory at www.woodward.com/directory, which also contains the most current product
support and contact information.
You can also contact the Woodward Customer Service Department at one of the following Woodward
facilities to obtain the address and phone number of the nearest facility at which you can obtain
information and service.
Products Used in Products Used in Products Used in Industrial

Electrical Power Systems Engine Systems Turbomachinery Systems
Facility --------------- Phone Number Facility --------------- Phone Number Facility --------------- Phone Number
Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800 Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727
Germany: Germany ------ +49 (711) 78954-510 India --------------- +91 (124) 4399500
Kempen---- +49 (0) 21 52 14 51 India --------------- +91 (124) 4399500 Japan---------------+81 (43) 213-2191
Stuttgart - +49 (711) 78954-510 Japan---------------+81 (43) 213-2191 Korea ---------------+82 (51) 636-7080
India --------------- +91 (124) 4399500 Korea ---------------+82 (51) 636-7080 The Netherlands--+31 (23) 5661111
Japan---------------+81 (43) 213-2191 The Netherlands--+31 (23) 5661111 Poland -------------- +48 12 295 13 00
Korea ---------------+82 (51) 636-7080 United States -----+1 (970) 482-5811 United States -----+1 (970) 482-5811
Poland -------------- +48 12 295 13 00
United States -----+1 (970) 482-5811
Woodward 53
Released
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
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information

Manufacturer
Turbine Model Number
Type of Fuel (gas, steam, etc.)
Power Output Rating

Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Serial Number
Control/Governor #3
Serial Number
Symptoms
Description
If you have an electronic or programmable control, please have the adjustment setting positions or the menu
settings written down and with you at the time of the call.
Woodward 54
Released
Revision History
Changes in Revision U-
 Replaced Warning on Page 28 regarding Bench Testing
 Added Figures 3-1, 3-2, and 3-3 as examples to illustrate the warning on Bench Testing
Changes in Revision T-
 Added content concerning connectors to the Electrical Connections section of Chapter 3
 Added content regarding piping loads and Table 3-1 to the Piping Installation section of Chapter 3
 Added notes clarifying dual lube port models in Chapter 4
Changes in Revision R-
 Removed cutaway drawing in Chapter 2
 Updated Cable drawings in Figures 3-1 and 3-4
Changes in Revision P-
 Deleted the Low Voltage Directive section
 Updated EMC directive, Pressure Equipment directive, and ATEX section
 Updated Max Fluid Temperature, and Max Fluid/Proof Test Pressures in Table 1-1
 Replaced DOC and DOI
Changes in Revision N-
 “SIL Certified” added to the title.
 Removed GOST R Certification from the Regulatory Compliance chapter
 Added an “Other International Compliance:” section to the Regulatory Compliance chapter and added
IECEx for the LELA Actuator
 Added an “EAC Customs Union:” section to the Regulatory Compliance chapter
 Added SIL Compliance section to the Regulatory Compliance chapter
 Added Ultra High Recovery valve specification in Chapter 1
 Added new Class 600 valve specifications in Chapter 1
 Added Class 600 engineering drawings in Chapter 1
 New 3-Inch Dimension “L” in Table 1-1 in Chapter 1
 Added Table 1-2 for ultra-high recovery valves to Chapter 1
 Deleted bolt size and torque table from Chapter 3
 Added new paragraph at the end of Piping Installation section in Chapter 3
 Added new cable drawings in Chapter 3
 Revised electrical connection drawings in Chapter 3
 Added Chapter 6, Safety Management – Safe Position Fuel Shutoff Function
Changes in Revision M—
 Updated Class 600 proof test pressure (page 10)
Changes in Revision L—
 Updated Regulatory Compliance information and Declarations
Woodward 55
Released
Declarations
Woodward 56
Released
Woodward 57
Released
We appreciate your comments about the content of our publications.

Send comments to: [email protected]
Please reference publication 26419.
ÌB26419è:èU¶¸µ¸´ºÎ
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.
Complete address / phone / fax / email information for all locations is available on our website.

SIL Certified Large Electric Sonic Valve (LESV) Gas Fuel Control Valve

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SIL Certified Large Electric Sonic Valve (LESV) Gas Fuel Control Valve

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Product Manual 26419

SIL Certified Large Electric Sonic Valve (LESV)

2-inch, 3-inch, 4-inch, 6-inch

Installation and Operation Manual

The latest version of most publications is available on the publications page. If

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

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

Manual 26419 LESV Gas Fuel Control Valve

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

Manual 26419 LESV Gas Fuel Control Valve

Illustrations and Tables

Figure 1-1a. Outline Drawing (2-Inch LESV Class 300) ............................................................................... 9

Table 1-1. LESV Large Electric Sonic Valve Specifications ......................................................................... 7

Manual 26419 LESV Gas Fuel Control Valve

Warnings and Notices

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

The products described in this publication may present risks that

Be prepared to make an emergency shutdown when starting the

Manual 26419 LESV Gas Fuel Control Valve

Electrostatic Discharge Awareness

Follow these precautions when working with or near the control.

Manual 26419 LESV Gas Fuel Control Valve

Other European Compliance:

Other International Compliance:

EAC Customs Union:

Manual 26419 LESV Gas Fuel Control Valve

North American Compliance:

CSA (Actuator): CSA Certified for Class I, Division 2, Groups A, B, C, & D, T3 at 93 °C

Actuator is certified for North America as on-engine systems component

Special Conditions for Safe Use:

EXPLOSION HAZARD—Do not remove covers or connect/disconnect

Substitution of components may impair suitability for Class I, Division

RISQUE D’EXPLOSION—Ne pas enlever les couvercles, ni

La substitution de composants peut rendre ce matériel

Manual 26419 LESV Gas Fuel Control Valve

Table 1-1. LESV Large Electric Sonic Valve Specifications

Manual 26419 LESV Gas Fuel Control Valve

Manual 26419 LESV Gas Fuel Control Valve

Figure 1-1a. Outline Drawing (2-Inch LESV Class 300)

Manual 26419 LESV Gas Fuel Control Valve

Figure 1-1b. Outline Drawing (2-Inch LESV Class 300)

Manual 26419 LESV Gas Fuel Control Valve

Figure 1-2a. Outline Drawing (2-Inch LESV Class 600)

Manual 26419 LESV Gas Fuel Control Valve

Figure 1-2b. Outline Drawing (2-Inch LESV Class 600)

Manual 26419 LESV Gas Fuel Control Valve

Figure 1-3a. Outline Drawing (3-Inch LESV Class 300)

Manual 26419 LESV Gas Fuel Control Valve

Figure 1-3b. Outline Drawing (3-Inch LESV Class 300)

Manual 26419 LESV Gas Fuel Control Valve

Figure 1-4a. Outline Drawing (3-Inch LESV Class 600)

Manual 26419 LESV Gas Fuel Control Valve

Figure 1-4b. Outline Drawing (3-Inch LESV Class 600)

Manual 26419 LESV Gas Fuel Control Valve

Figure 1-5a. Outline Drawing (4-Inch LESV Class 300)

Manual 26419 LESV Gas Fuel Control Valve

Figure 1-5b. Outline Drawing (4-Inch LESV Class 300)

Manual 26419 LESV Gas Fuel Control Valve