Woodward High Output Digital Valve Positioner (DVP) DVP5000/DVP10000/DVP12000

High Output Digital Valve Positioner (DVP)

DVP5000/DVP10000/DVP12000

The Digital Valve Positioner (DVP) is a family of purpose-built digital electronic positioners and actuator

drivers used to control actuation systems on gas and steam turbines. The DVP is designed to control

valves and actuators with brushless DC (BLDC) motor types. The driver controls actuator/valve position

based on resolver and LVDT feedback located on the valve and/or actuator. The DVP supports both

resolver and LVDT feedback devices. The DVP5000. DVP10000. and DVP12000 use the latest in

Woodward control architecture and a robust controller to provide high-speed precise valve control. The

DVP5000 provides a nominal 5 kW output, the DVP10000 is capable of a nominal 10 kW output, and the

DVP12000 is capable of a nominal 12kW output.

The DVP5000/DVP10000/DVP12000 products are an extension of the existing DVP family. These units

are rear-panel mounted and utilize forced air cooling to provide high power output with an extended

operating ambient of -40°C to +70°C. The maximum output is 25Adc or 25Apk (17.7Arms) and the driver

accepts an input voltage from 90 V to 300 VDC, the output current for the DVP10000 and DVP12000 is

derated below an input voltage of 190 VDC. The DVP12000 can provide an increased output current of

28Adc or 28Apk (19.8Arms) when operating with select actuators in ambient temperatures between -40°C

to 55°C. For functional safety applications, the DVP5000/DVP10000/DVP12000 has an EXTERNAL

SHUTDOWN discrete input that can be used as a remote shutdown command that is independent of the

CPU. This feature is optionally available and certified to SIL3 per IEC61508. SIL certified versions are

identified by the DVP5000-S, DVP10000-S, and DVP12000-S labels on the front panel. All other I/O and

control features are identical to the existing DVP family.

The DVP10000 and DVP12000 have a power module that temporarily boosts output power as necessary

to attain the required motor performance. These packages are slightly wider, but otherwise have the

same I/O connections as the DVP5000. Some electrical specifications are different. See the Electrical

Specifications section for more details.

In this manual, the term DVP is sometimes used to more concisely describe the DVP5000. DVP10000.

and DVP12000 products.

The DVP is designed for plug-and-play installations on many Woodward valve and actuator types.

Woodward has integrated a smart technology device called an ID (identification) module into our latest

valves and actuators. When the DVP is connected to a valve or actuator equipped with an ID module, the

DVP will automatically detect the type of valve or actuator and read critical set up and calibration

information necessary to configure the driver to the valve or actuator. After the customer interface

configuration, the DVP is ready for use.

The DVP is designed to accept many different types of input commands, including Single or Dual CAN,

Analog Input (4–20 mA or 0–5 V), or Ethernet (if equipped). Woodward also provided a Service Tool that

allows users to manipulate, configure, and monitor the DVP operation status.

The Woodward DVP5000/DVP10000 and DVP12000 are suitable for +125 VDC or 220 VDC nominal

input voltage supply operation. Contact Woodward for additional voltage options.

1.2 Purpose and Scope

The purpose of this manual is to provide the necessary background information for installing and

operating the Digital Valve Positioner (DVP) appropriately. Topics covered include introduction, basic

functional description, mechanical installation, and electrical wiring. Troubleshooting and basic software

tool installation and operation is covered in this manual.

1.3 Intended Applications

The Woodward DVP5000. DVP10000. and DVP12000 are purpose-built, state-of the-art drivers for

electric actuation. These versions feature a rugged and compact design. The DVP provides positioning

based on a demand signal from the control system and monitors the health of the driver/actuator

subsystem. Multiple input type configurations allow use of the DVP with many different turbine controllers.

The DVP also supports redundant installations. The DVP provides significant advancements over the

earlier generation of the driver, including internal configurability to drive different Woodward products.

Connect all wires as shown in the plant-wiring diagram for the appropriate actuator type. Refer to the

appropriate valve/actuator manual for wiring diagrams.

• Load terminations should be applied accordingly.

• Apply general practice to ensure cables are checked from point to point. Motor and position feedback

transducer impedance are verified from line power to ground.

• Wires exposed beyond the shield should be as short as possible, not exceeding 2 inches (51 mm).

• The shield termination wire (or drain wire) should be kept as short as possible, not exceeding 2

inches (51 mm), and where possible the diameter should be maximized.

• Installations with severe electromagnetic interference (EMI) may require additional shielding

precautions. Contact Woodward for more information.

Failure to provide shielding can produce future conditions which are difficult to diagnose. Proper shielding

at the time of installation is required to assure satisfactory operation of the product.

Verify details concerning installation mounting requirements: Ground straps, lock washers, etc.

2.5 Mechanical Installation Requirements

This section provides the general information for mounting location selection, installation, and wiring of

the Digital Valve Positioner (DVP).

2.5.1. Unpacking the Shipping Carton

• Before unpacking the control, refer to the inside front cover of this manual and to the Regulatory

Compliance page for warnings and cautions. Be careful when unpacking the control. Check for signs

of damage such as bent or dented panels, scratches, and loose or broken parts. If any damage is

found immediately notify the shipper.

• The DVP is shipped from the factory in an antistatic foam-lined carton. This carton should always be

used for transport of the DVP when it is not installed. Read the Electrostatic Discharge Awareness

page before handling the DVP.

• Check for and remove all manuals, connectors, mounting screws, and other items before discarding

the shipping box.

2.5.2. General Installation and Mounting Considerations

When selecting a location for mounting the DVP consider the following:

• Protect the unit from direct exposure to water or a condensation-prone environment.

• The DVP is designed for installation in a low vibration environment. If installed in vibration levels

above normal control room levels, the DVP should be vibration isolated from engine and generator

vibrations above 50 Hz. See Grounding Requirements above.

• Install the DVP5000/DVP10000 in an area where the operating temperatures will not exceed -40°C

to +70°C (-40°F to +158°F).

• Install the DVP12000 in an area where the operating ambient temperatures will not exceed -40°C to

+70°C (-40°F to +158°F) for 25A operation and -40°C to +55°C (-40°F to +131°F) for 28A operation.

The Woodward Actuator/Valve determines the DVP12000 operating current.

• The DVP is designed for rear panel mounting to a metal surface and adequate clearance around the

air intake and exhaust openings.

• The DVP can be mounted in any orientation with proper clearance provided to allow air flow. For

maximum thermal performance, the DVP must be mounted in a vertical orientation.

• Shield the unit from radiant heat sources.

• Allow adequate space around the unit for servicing and cable routing.

• Do not install near high-voltage or high-current devices.

• Install the DVP in an area where there is a protection from outside contamination.

• Installation Clearance: 6 inches on the top and 6 inches on the bottom in addition to proper airflow

ventilation in the cabinet for 100 CFM (or 2.8 cubic meters/minute) of unobstructed airflow per unit.

No clearance is required on the sides for cooling.

• Verify that cable lengths do not exceed lengths specified in the electrical I/O section of this manual.

• Refer to Technical Specifications for packaging heat load information

2.5.3. Wire Preparation and Connector Screw Torque Drive Recommendation

Woodward recommends that the following wire preparation and terminal block screw torque specifications

for all DVP input/output terminal blocks.

Note: Stranded wire is recommended.

Table 2-1. Wire Hookup Guideline

Specification

I/O Terminal Block

Power Terminal Blocks

Wire Gauge

20 – 16 AWG

(0.5 – 1.0 mm²)

8 to 18 AWG 1

6 to 18 AWG 2

(0.75 to 6 mm²)

Wire Strip

Length

0.25 – 0.300 Inches

(6.4–7.6 mm)

0.45 – 0.55 Inches

(11.4–14.0 mm)

Recommended

Torque drive on

the Terminal

Block Connector

2.5 – 3.5 lb-in

(0.3 – 0.4 Nm)

Table Notes

1- 8 to 18AWG is for DVP5000 and DVP10000

2 – 6 to 18 AWG is for DVP12000

2.5.4. Connector Kits

10 – 12 lb-in

(1.1 – 1.4 Nm)

The DVP is shipped with mating connectors for all input and output connectors. However, in some

applications where an extra set of connectors is needed, Woodward carries a connector kit as shown on

Table 2-2.

2.5.5. DVP 5000 and DVP10000 Configuration Options

The DVP10000 is the same as the DVP5000 with the addition of a boost module to increase power

temporarily to meet high performance actuator requirements. The DVP10000 package is slightly wider

than the DVP5000 to accommodate the boost module.

The DVP12000 is the same as the DVP10000 with a temperature derating option for higher output current

availability and the ability to operate with spring return actuators.

Additional Options:

• EXTERNAL SHUTDOWN feature is optionally certified to a SIL 3 level. The certified versions are

indicated on the front panel by DVP5000-S, DVP10000-S and DVP12000-S labels.

• Optional Ethernet Communication capability.

2.5.6. Terminal Locations

All terminals and connectors are located on the front panel of the chassis. Figures 2-2 and 2-3 show the

front panel and outline views. For EMC compliance, mount the DVP with low impedance bond to Earth

ground.

2.6 Fan Assembly Replacement

The fan assembly in the DVP is designed for field replacement if necessary. If one or both fans fail, an

alarm is generated.

The fans are a ball bearing type with a nominal airflow of 51.97 CFM (1.47m3/min) each.

A degraded fan can occasionally be identified by audible noise sounding like a low rumbling or roughness

from the bearings. In this case, it is advisable to replace the fan assembly at the earliest opportunity.

The fan L10 life is rated at 30.000 hours @ 40C. To extend fan life, the DVP switches fan speed at

several internally sensed temperatures to provide optimum balance between cooling and fan life.

Woodward recommends fan assembly replacement every five years of operation.

The fan assembly orderable part number is 8926-1045SPR.

The following procedure is used to replace the fan assembly for the DVP; see Figure 2-5.

Place the actuator into a safe state.

Ensure that input power is removed from the driver.

Unscrew the 3 retention screws. Using the handle, remove the fan assembly from the DVP.

Place the new fan assembly into the connector; tighten the three retention screws.

Apply power to the DVP and ensure the fan alarms are off.

3.1 Power Supply Inputs

The DVP is designed with redundant power supply inputs. These inputs share a common ground and are

isolated from chassis ground. This option allows for redundancy in wiring, connectors, and power sources if

the power sources share a common ground. If one of the inputs is lost, drops low, or experiences temporary

power loss, the other power input will take over without being affected by the first input. The user is provided

four terminals—two plus and two minus. The DVP requires a power supply capable of the specified voltages

and current levels. Please see Table 3-1 for power and fusing information necessary for safe and reliable

operation of the DVP.

3.1.1. Inrush Limiting

The DVP has current inrush limiting built into the design. Power to the CPU occurs rapidly after power

application, but the internal bulk storage capacitors take about eight seconds to fully charge. Inverter

activation is prevented by software until the inrush time has expired. This inrush sequence occurs after

BOTH input power is applied AND EXTERNAL SHUTDOWN input is energized.

3.2 Power Wiring

3.2.1. Recommended Minimum Input Protection:

DVP5000: 15A time delay fuse or 15A breaker

DVP10000 and DVP12000: 30A time delay fuse or 35A breaker (Ambient temperature -40oC to +70oC)

DVP12000: 40A time delay fuse or 45A breaker (Ambient temperature -40oC to +55oC)

High input current transients can be drawn during rapid load movement. The above recommendations

include the transient nature of the electrically driven actuator system. The DVP is not equipped with an

input power switch or breaker. Correct sizing depends on factors such as cable sizing, environment, and

local regulatory requirements. It is recommended that a safety input power switch be provided for

installation and servicing.

Proper input power wiring to the DVP is crucial to its operation. A circuit breaker meeting the power

supply requirement may be used for this purpose. It is important that proper wiring be applied during

system installation to avoid an unwanted power trip or ground loop. Figure 3-1 illustrates the correct and

incorrect power cable wiring.

3.2.2 Recommendations for Dual and Simplex Power Wiring

The DVP is provided with power terminals suitable for the required voltage and current level. Two positive

and two negative pins are each sized for 8 AWG wire for the DVP5000 and DVP10000. The DVP12000

can accommodate up to 6 AWG wire.

Provision for separate redundant power supplies is provided by dual DC inputs. Each of the inputs is

diode isolated from the main input bus. If one of the supplies is lost, the other input will take over and the

DVP will continue to operate normally. The loss of the input will be annunciated as an alarm.

Woodward recommends that you take advantage of the dual input power wiring configuration; however,

the inputs can be tied together for use with a single power supply.

If a single power source is used to supply power to the DVP, jumpers should be used to apply power to

both sets of input power terminals. The purpose of these jumpers is to ensure that the power supplied

from the source is distributed equally to the two DVP inputs. This minimizes the power dissipated in each

of the DVP input diodes for reduced heat load and improved reliability. When using the jumpers, insert the

positive (+) power input lead from the power source into either the #1 or #3 positions, and the negative (-)

lead into either the #2 or #4 positions as shown in Figure 3-2a.

Some newer versions of the DVP may include power input plugs with jumpers to connect the two positive

and two negative terminals.

In installations where separate dual power sources are connected to the DVP, as shown in Figure 3-2b,

the jumpers are not required.