Installation and Operation Manual

EM35MR1 Electric Powered Actuator

and 3103 Gas Valve

Manual 40185 (Revision G)

 WARNING—DANGER OF DEATH OR PERSONAL INJURY
WARNING—FOLLOW INSTRUCTIONS
Read this entire manual and all other publications pertaining to the work to be performed
before installing, operating, or servicing this equipment. Practice all plant and safety
instructions and precautions. Failure to follow instructions can cause personal injury and/or
property damage.
WARNING—OUT-OF-DATE PUBLICATION
This publication may have been revised or updated since this copy was produced. To verify
that you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The
latest version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get
the latest copy.
WARNING—OVERSPEED PROTECTION
The engine, turbine, or other type of prime mover should be equipped with an overspeed
shutdown device to protect against runaway or damage to the prime mover with possible
personal injury, loss of life, or property damage.
The overspeed shutdown device must be totally independent of the prime mover control
system. An overtemperature or overpressure shutdown device may also be needed for
safety, as appropriate.
WARNING—PROPER USE
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 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.

CAUTION—POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY

CAUTION—BATTERY CHARGING
To prevent damage to a control system that uses an alternator or battery-charging device,
make sure the charging device is turned off before disconnecting the battery from the system.
CAUTION—ELECTROSTATIC DISCHARGE
Electronic controls contain static-sensitive parts. Observe the following precautions to
prevent damage to these parts.
• Discharge body static before handling the control (with power to the control turned off,
contact a grounded surface and maintain contact while handling the control).
• Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around printed circuit
boards.
• Do not touch the components or conductors on a printed circuit board with your hands
or with conductive devices.

IMPORTANT DEFINITIONS
• A WARNING indicates a potentially hazardous situation which, if not avoided, could result in
death or serious injury.
• A CAUTION indicates a potentially hazardous situation which, if not avoided, could result in
damage to equipment or property.
• A NOTE provides other helpful information that does not fall under the warning or caution
categories.

Revisions—Text changes are indicated by a black line alongside the text.

Woodward Governor Company reserves the right to update any portion of this publication at any time.
Information provided by Woodward Governor Company is believed to be correct and reliable. However, no
responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1999
All Rights Reserved
Manual 40185 EM35MR1/3103 Gas Valve

Contents

REGULATORY COMPLIANCE ........................................................................ II 

ELECTROSTATIC DISCHARGE AWARENESS ................................................. IV 
CHAPTER 1. GENERAL INFORMATION ........................................................... 1 
Introduction .............................................................................................................1 
3103 Gas Valve ......................................................................................................1 
EM35MR1 Actuator ................................................................................................2 
Resolver..................................................................................................................2 
CHAPTER 2. INSTALLATION.......................................................................... 3 
Unpacking ...............................................................................................................3 
Power Requirements ..............................................................................................3 
EM Actuator/3103 Gas Valve Installation ...............................................................8 
Electrical Connections ............................................................................................8 
CHAPTER 3. DESCRIPTION OF OPERATION ................................................. 11 
EM35MR1 Actuator ..............................................................................................11 
3103 Gas Valve ....................................................................................................11 
CHAPTER 4. ACTUATOR/VALVE CALIBRATION ........................................... 12 
EM35MR1 Actuator/3103 Gas Valve with Driver .................................................12 
CHAPTER 5. TROUBLESHOOTING ............................................................... 13 
General .................................................................................................................13 
Procedure for EM35 Actuator Field Replacement ................................................13 
CHAPTER 6. VALVE SIZING—NON-DLE APPLICATIONS .............................. 16 
Determination of Effective Area ............................................................................16 
Valve Sizing and the Effective Area Tables .........................................................17 
Determining the Demand Required to Achieve Specific Flows ............................18 
CHAPTER 7. MAINTENANCE ....................................................................... 22 
CHAPTER 8. SERVICE OPTIONS ................................................................. 23 
Product Service Options .......................................................................................23 
Returning Equipment for Repair ...........................................................................24 
Replacement Parts ...............................................................................................25 
How to Contact Woodward ...................................................................................25 
Engineering Services............................................................................................26 
Technical Assistance ............................................................................................27 
EM35MR1/3103 SPECIFICATIONS ............................................................. 29 
DECLARATIONS ......................................................................................... 30 

Illustrations and Tables

Figure 2-1. EM35MR1 Actuator/3103 Gas Valve/Resolver Outline .......................5 

Figure 2-2. EM35MR1 Actuator/3103 Gas Valve/Resolver Outline .......................7 
Figure 2-3. WAGO 264 Series Terminal Block.....................................................10 

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EM35MR1/3103 Gas Valve Manual 40185

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

European Compliance for CE Marking:

Pressure Equipment Directive Certified to Pressure Equipment Directive
(Valve): 97/23/EC of 29 May 1997 on the approximation
of the laws of the Member States concerning
pressure equipment, Category II. Moody
International Certificate 90 174.

ATEX—Potentially Explosive Declared to 94/9/EEC COUNCIL DIRECTIVE of

Atmospheres Directive 23 March 1994 on the approximation of the laws
(Actuator, Resolver, Valve): of the Member States concerning equipment and
protective systems intended for use in potentially
explosive atmospheres.
LCIE 02 ATEX 6140 X Zone 1, Category 2,
Group II G, EEx d IIB T3 X (Actuator)
LCIE 02 ATEX 6141 X Zone 1, Category 2,
Group II G, EEx d IIB T3 X (Resolver)
Zone 1, Category 2, Group IIG c II X (3103
Valve)

NOTE
EM-35/EM35MR1 Actuator and 3103 Valve assemblies incorporating the
minimum position switch are not suitable for use in an ATEX environment.

Other European Compliance:

Compliance with the following European Directives or standards does not qualify this
product for application of the CE Marking:

EMC Directive: Compliance as a passive component to

89/336/EEC COUNCIL DIRECTIVE of 03 May
1989 on the approximation of the laws of the
Member States relating to electromagnetic
compatibility. Meets the surge requirements of
EN 61000-6-2.

Machinery Directive: Compliance as a component with 98/37/EC

COUNCIL DIRECTIVE of 23 July 1998 on the
approximation of the laws of the Member States
relating to machinery.

North American Compliance:

These listings are limited only to those units bearing the UL and/or CSA identification.

Suitability for use in North American Hazardous Locations is the result of compliance of
the individual components:

Actuator: CSA Certified for Class I, Division 1, Groups C & D, Class I,

Division 2, Groups B, C, and D, T3 at 149 °C Ambient. For use
in Canada and the United States.

Minimum Position CSA Certified for Class I, Division 1, Groups C & D, Class II,
Switch: Division 2, Groups E, F, and G. LR57324.
UL Listed for Class I, Division 1, Groups C & D, Class II,
Division 2, Groups E, F, and G. E14274.

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Manual 40185 EM35MR1/3103 Gas Valve

Special Conditions for Safe Use

Wiring must be in accordance with North American Class I, Division 1 or 2 or European
Zone 1 wiring methods as applicable, and in accordance with the authority having
jurisdiction.

Ambient Temperature and

Fuel Temperature –40 to +149 °C (–40 to +300 °F)
Ambient Temperature and
Fuel Temperature
(Restriction for CE Marking) –29 to +149 °C (–20 to +300 °F)

Use supply wires suitable for a maximum ambient temperature of +149 °C.

For ATEX Zone 1 and Zone 2 Applications: A conduit seal must be installed within 50 mm
(2 inches) of the conduit entries when the EM35MR1 Actuator and EM Resolvers are used
in a Zone 1 or a Zone 2 ATEX classified explosive atmosphere. These are Category 2,
flameproof, type 'd' products.

For Class I, Division 1 or Class I, Zone 1 North American Applications: A conduit seal
must be installed within 457 mm (18 inches) of the conduit entry when the EM35MR1
Actuator or EM Resolvers are used in a Class I, Division 1 or Class I, Zone 1 hazardous
atmosphere.

The surface of the gas valve is dependent upon the temperature of the fuel. Refer to the
burn hazard warning statement below for safe handling. Fuel temperature effects on valve
surface temperature must be taken into consideration when this product is used in an
explosive atmosphere.

WARNING—BURN HAZARD
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.

WARNING—EXPLOSION HAZARD
Do not connect or disconnect while circuit is live unless area is known to be
non-hazardous.

Substitution of components may impair suitability for Class I, Division 1 or 2

or Zone 1 or 2 applications.

AVERTISSEMENT—RISQUE D’EXPLOSION
Ne pas raccorder ni débrancher tant que l’installation est sous tension, sauf
en cas l’ambiance est décidément non dangereuse.

La substitution de composants peut rendre ce matériel inacceptable pour les

emplacements de Classe I, applications Division 1 ou 2 ou Zone 1 ou 2.

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Electrostatic Discharge Awareness

All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.

Follow these precautions when working with or near the control.

1. Before doing maintenance on the electronic control, discharge the static

electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).

2. 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.

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.

4. 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.

CAUTION—ELECTROSTATIC DISCHARGE
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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Manual 40185 EM35MR1/3103 Gas Valve

Chapter 1.
General Information

Introduction
The EM35MR1 electric actuator is used to drive a 3103 gas valve, closed loop to
position demand. Position feedback is provided by a resolver connected to the
valve metering sleeve. Closed loop position control is accomplished through an
EM 24V Digital Driver. Having the feedback on the valve allows the motor
assembly to be repaired or changed in the field without the loss of valve
calibration.

3103 Gas Valve

The 3103 Gas Valve is a stainless steel valve capable of metering gas flow
between 23 and 18 144 kg/h (50 and 40 000 lb/h). The valve is designed to bolt
into a 2 inch (51 mm) line by means of 0.625-11 UNC 2B tapped holes. The
flange is class 600 per ANSI B16.5. The valve design is a rotary metering sleeve
and a shoe-type throttling valve. The valve shoe is spring- and pressure-loaded
against the metering port to minimize leakage and to self-clean the metering port.
Metering port area is determined by input shaft positioning from the actuator. The
valve has an internal spring to return the valve to the minimum fuel position in the
event of a power loss to the actuator.

The 3103 valve has redundant seals on all dynamic sealing surfaces. Between
these two seals is an overboard vent which vents any gasses that may leak past
the first seal to safe vent location. The use of an inner-seal vent prevents the
second dynamic seal from seeing any differential pressure and thus offers
protection against the leakage of gasses from the valve into the surrounding
ambient atmosphere.

The valve design incorporates an inlet guide tube to condition the inlet flow and
to direct any gas contaminants through the metering port, minimizing any
accumulation in the valve housing. The metering sleeve support bearings are
positively sealed from the gas. Internal valve parts are made of through-
hardened stainless steel.

CAUTION—DO NOT ADJUST STOPS

The valve has mechanical stop screws installed in the valve flange. These
stops must not be adjusted by the customer. If these stops interfere with the
valve operating region or the electrical stops, it will cause the EM 24V Digital
Driver to trip out on overcurrent.

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EM35MR1/3103 Gas Valve Manual 40185

EM35MR1 Actuator
The EM35MR1 actuator is an all-electric actuator designed for use in industrial
gas turbine control applications. The EM35MR1 actuator consists of a high
performance brushless servomotor and a precision planetary gearbox with two
resolver-type shaft position sensors. All stator windings are completely sealed
The use of a high efficiency gearbox facilitates high servo system bandwidth. The
motor has its own resolver providing motor rotor position feedback, and the other
resolver(s) provides accurate output shaft position feedback. The actuator also
has a slip clutch to allow full speed impact into optional external rigid mechanical
stops.

The motor assembly is housed in a cast aluminum explosion proof housing. A

thermal potting compound is used to transfer waste heat generated by the motor,
to the cast, explosion-proof housing and out to the ambient environment. Wiring
to the motor is accomplished through two .750-14 NPT conduit connections or
two M25 x 1.5 conduit connections into a wiring compartment integral to the
housing. One conduit is for the motor power wires, the other is for the motor
resolver wires. The motor output shaft is directly coupled to the valve input shaft
through the use of a stainless steel torsional coupling.

Resolver
Position feedback is accomplished using a highly accurate brushless resolver(s).
The resolver is directly coupled to the valve metering shaft through use of a
stainless steel bellows and is housed in an explosion proof enclosure. The
resolver receives its excitation from the EM driver. The EM driver uses a
resolver-to-digital converter to determine valve position using the output voltages
from the resolver's two secondary windings. Resolver accuracy is ±0.05°. Wiring
to the resolver is accomplished through two .750-14 NPT conduit connections or
two M25 x 1.5 conduit connections.

2 Woodward
Manual 40185 EM35MR1/3103 Gas Valve

Chapter 2.
Installation

Unpacking
Be careful when unpacking the EM 24 V Digital Driver and EM35MR1
actuator/3103 gas valve. Check the devices for signs of damage such as bent or
dented case and loose or broken parts. If damage is found, notify the shipper
immediately. The devices may be stored in their original shipping containers until
they are ready for installation. Protect the devices from weather and from
extreme humidity or temperature fluctuations during storage.

WARNING—LIFTING
The EM35MR1/3103 assembly weight is approximately 44 kg (96 lb). In order
to prevent injury, a lifting strap or other means of lifting assistance should
be used when handling this product.

WARNING—NOISE
Due to typical noise levels in turbine environments, hearing protection
should be worn when working on or around the 3103 Gas Valve.

WARNING—BURN HAZARD
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.

CAUTION—FIRE HAZARD
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.

Power Requirements
The EM35MR1 actuator receives all of its power from the EM driver. The full
actuator operating range of the actuator is 18–32 Vdc. The maximum steady
state driver input current is 15 A continuous with peaks of 37 A for 50 ms.

WARNING—EXPLOSION HAZARD
For Zone 1 / Division 1 products: Proper torque is very important to ensure
that the unit is sealed properly. Actuator cover bolt torque is:
0.250-28 socket head cap screw = 9.2 Nxm (81 lb-in)
M6 x 1 socket head cap screw = 8.0 Nxm (71 lb-in)
Resolver cover bolt torque is 9.2 Nxm (81 lb-in).

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EM35MR1/3103 Gas Valve Manual 40185

4 Woodward
Manual 40185 EM35MR1/3103 Gas Valve

Figure 2-1. EM35MR1 Actuator/3103 Gas Valve/Resolver Outline

(NPT electrical conduit entries)

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EM35MR1/3103 Gas Valve Manual 40185

6 Woodward
Manual 40185 EM35MR1/3103 Gas Valve

Figure 2-2. EM35MR1 Actuator/3103 Gas Valve/Resolver Outline

(metric electrical conduit entries)

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EM35MR1/3103 Gas Valve Manual 40185

EM Actuator/3103 Gas Valve Installation

For most applications, the valve/actuator assembly can be supported by the 2
inch (51 mm) flanges when bolted into the system piping. For applications where
this is not practical or where additional support is required, the assembly can be
bolted to a supporting structure by the four 0.625-11 UNC-2B tapped holes in the
valve base.

See Figures 2-1 and 2-2 for overall dimensions, installation hole locations, and
any fitting or plumbing connections. Installation attitude does not affect valve/
actuator performance.

Make sure that adequate room is allowed for required wiring and that the wiring
and valve/actuator are accessible for service.

There are two overboard drains on the 3103 valve (see Figures 2-1 and 2-2).
One is to be plumbed to an area outside the turbine enclosure. Use the
overboard drain most convenient for your installation and plug the one that is not
used. This drain vents the cavities between the inner and outer seals on both
ends of the valve shaft.

WARNING—EXPLOSION HAZARD
The overboard drain port vents process fuel to the atmosphere. The
overboard drain gas volume may increase as temperatures drop below 0 °C
(32 °F). Plan the vent system, taking temperature affects into consideration.
Vent the drain ports to a safe location away from the turbine enclosure or
any hazardous location / explosive atmosphere. Protect the vent line from
obstruction, physical damage, condensation, or corrosion.

CAUTION—DO NOT PLUG DRAIN

DO NOT plug both drains. This can cause pressure to build up in the vent
cavity and potentially damage the valve.

NOTE
It is recommended that the end of the line (outside the enclosure) be placed
in a small container of clean, lightweight oil to check for gas leakage. This
will also prevent a corrosive or salt air atmosphere from corroding the shaft
bearings which are in the cavity between the shaft seals.

Electrical Connections
Shielded Wiring
1. All shielded cable must be twisted conductor pairs with either a foil or a
braided shield.
2. All signal lines should be shielded to prevent picking up stray signals from
adjacent equipment.
3. Connect the shields as shown in the plant wiring diagram in EM Driver
manual 26159. Wire exposed beyond the shield must not exceed two inches.
The other end of the shield must be left open and insulated from any other
conductor.
4. Do not run shielded signal wires with other wires carrying large currents.
5. See Manual 50532, EMI Control in Electronic Governing Systems, for more
information.

8 Woodward
Manual 40185 EM35MR1/3103 Gas Valve
Installations with severe electromagnetic interference (EMI) may require shielded
cable run in conduit, double shielded wire, or other precautions. Contact
Woodward for more information.

WARNING—EXPLOSION HAZARD
Do not connect or disconnect while circuit is live unless area is known to be
non-hazardous.

Substitution of components may impair suitability for Class I, Division or

Zone applications.

AVERTISSEMENT—RISQUE D’EXPLOSION
Ne pas raccorder ni débrancher tant que l’installation est sous tension, sauf
en cas l’ambiance est décidément non dangereuse.

La substitution de composants peut rendre ce matériel inacceptable pour les

emplacements de Classe I, applications Division ou Zone.

CAUTION—COVER
Take care not to damage the cover seal, the cover surface, the threads, or
the actuator or resolver surface while removing or replacing the cover.

NOTE
The EM35MR1 Actuator and EM Resolvers are certified as type ‘d’
(flameproof enclosure) ATEX Category 2 equipment, suitable for use in a
Zone 1 explosive atmosphere. Wiring methods must comply with this Zone
1-Category 2 method of protection when installed in either a Zone 1 or a
Zone 2 classified atmosphere. Conduit seals are required. Refer to the
Special Conditions for Safe Use stated on page iii.

WARNING—EXPLOSION HAZARD
For Zone 1 / Division 1 products: Proper torque is very important to ensure
that the unit is sealed properly. Actuator cover bolt torque is:
0.250-28 socket head cap screw = 9.2 Nxm (81 lb-in)
M6 x 1 socket head cap screw = 8.0 Nxm (71 lb-in)
Resolver cover bolt torque is 9.2 Nxm (81 lb-in).

Plant Wiring

CAUTION—WIRING
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.

Consult the EM Driver manual (26159) for plant wiring diagram, and for specific
wiring requirements and procedures.

1. Power wiring between the motor and the driver: Any extra motor wire in the
installation should be cut off and discarded, not coiled.

NOTE
Coiled wire will cause an inductance that could be greater than that of the
motor.
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EM35MR1/3103 Gas Valve Manual 40185
2. The metering valve is not shipped with any field wiring attached (such as
pigtails) but rather is provided with internal terminal blocks for field wiring.
These terminal blocks are located under the explosion proof covers on the
actuator and resolver housings.
3. The non-metric actuator housing has two 0.75 inch NPT taps and the
resolver housing has two .750-14 NPT taps. The metric actuator housing has
two M25 x 1.5 taps and the resolver housing has two M25 x 1.5 taps.
4. The resolver wires need to be run through the wiring connection in front of
the 10 pole WAGO® terminal block. The actuator power wires should go
through the other wiring connection.

The terminal blocks provided for the motor resolver wires and the position
resolver are WAGO 264 series. These terminal blocks are top load terminal
blocks and are actuated by inserting a DIN 5264 screwdriver into the opening
behind the wire slot. Once the cage clamp has been opened, the wire can be
inserted and the screwdriver removed. Please see the illustration and instructions
below.

The screwdriver is inserted into the operating slot up to the stop.

1. Insert the screwdriver into the operating slot up to the stop.

2. Use the screwdriver blade to hold the clamping spring open so that the
conductor can be introduced into the clamping unit.
3. Withdraw the screwdriver. The conductor is automatically clamped.

Figure 2-3. WAGO 264 Series Terminal Block

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Manual 40185 EM35MR1/3103 Gas Valve

Chapter 3.
Description of Operation

EM35MR1 Actuator
The EM35MR1 electric actuator is comprised of a brushless dc motor, a clutch
assembly, a gearhead assembly, and an explosion proof housing. The brushless
dc motor uses Samarium Cobalt permanent magnets bonded and sleeved to the
rotor. The high speed motor output shaft is clutched before the gearbox
assembly. This clutch prevents damage to the motor shaft and gearbox should
an external force suddenly stop the rotation of the gearbox output shaft. The
clutch slips at 1.5 times the maximum output force of the motor/gearbox
assembly. The motor gearbox is a planetary gearbox and is used to reduce the
output speed and increase the output torque.

The control signals for the motor come from an external motor driver. The motor
driver handles motor commutation as well as closed loop position control. The
position feedback comes from a precision resolver directly coupled to the valve
metering sleeve. This arrangement prevents any errors in sensing the desired
valve position through linkages and gear trains and results in precise position
control. Having the feedback on the valve also allows for the motor to be repaired
or replaced in the field without any loss of calibration.

The entire motor assembly is installed in a cast explosion proof housing. The
motor is heat sunk to this external housing to allow heat generated by the motor
to be effectively transferred to the ambient environment.

The output shaft of the gear train is supported by two roller bearings. To minimize
side load to the motor the output shaft is directly coupled to the valve using a
stainless steel torsional coupling. The torsional coupling efficiently transmits the
motor torque to the valve with very little lost motion and is key to achieving the
desired position control of the valve.

3103 Gas Valve

Actuator output shaft movement positions the gas valve metering sleeve and
resolver. Gas flow is metered at the valve through a ported rotary sleeve. Gas
enters the inlet port (P1) where it is directed through the inlet guide tube to the
rotary metering port. A spring and pressure loaded, sharp edged shoe seals
against the metering sleeve. Metered fuel is discharged at the outlet pressure.
Metered fuel is determined by valve position, inlet pressure (P1), outlet pressure
(P2), gas temperature, and gas composition.

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EM35MR1/3103 Gas Valve Manual 40185

Chapter 4.
Actuator/Valve Calibration

EM35MR1 Actuator/3103 Gas Valve with Driver

For calibration details, see the Dry Low Emissions, Fuel Metering Valves:
Warnings, Calibration, and Installation manual (40142). For non-DLE systems
see the EM 24 V Digital Driver manual (26159).

The EM35MR1 actuator/gas valves used with the digital driver is typically for
applications that require extremely high accuracy, like dry low emissions (DLE)
control. For that reason, all calibration of the actuator/valve assembly is
performed at the factory.

The mechanical stops on the valve limit valve travel and prevent damage to the
valve caused by driving it beyond its normal range. Flow calibration is achieved
using the digital resolver feedback and a valve characterization table. The flow
vs. angle data is determined for each valve during the flow testing and is
recorded on a floppy disk.

No field rigging is required to calibrate the valve. There is a warning tag on the
valve and a warning message on the operator panel stating that the table
identification (serial number and date code) must match the valve identification.

For non-DLE applications, Woodward offers a series of standard EM35MR1/3103

valves. From the factory, these valves have the minimum and maximum stops
set outside the normal operating window of 0 to 60 degrees valve travel, and the
flow calibration schedule is not for a specific application. To determine the
minimum and maximum flow valve positions, and any intermediate open loop
flow schedule points, follow the steps in Chapter 6: Valve Sizing.

WARNING—PROPER PROGRAMMING/SETUP
Significant turbine damage, high emissions levels, release of high
temperature gas, fire, damage to nearby equipment, injury to personnel, or
death may result from incorrect fuel valve calibration. To correctly operate
the fuel metering valve(s), the MicroNet™ or NetCon® controller must be
programmed with the correct valve characterization curve for the specific
valve being used. Woodward provides the programming information to the
valve purchaser in the form of a data file specifically identified by the valve
serial number and date. The supplier of the application program must
incorporate the valve characterization data file into the application program
by following the procedure described in this manual. Failure to follow the
procedure herein, or any non-Woodward alteration (including attempt to
repair), or damage to the valve, may result in a change of characteristics
leading to the same potential hazards.

WARNING—START-UP
Be prepared to make an emergency shutdown when starting the engine,
turbine, or other type of prime mover, to protect against runaway or
overspeed with possible personal injury, loss of life, or property damage.

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Manual 40185 EM35MR1/3103 Gas Valve

Chapter 5.
Troubleshooting

General
Faults in the governing system are usually revealed as speed variations of the
prime mover, but it does not necessarily follow that such speed variations
indicate governing system faults. Therefore, when improper speed variations
appear, check all components including the prime mover for proper operation.

Problems with the EM/valve assembly will usually show up as faults in the driver.
Refer to the appropriate EM 24 V Driver manual (26159) for detailed fault
information.

Overcurrent trips experienced by the driver can be caused by driving the valve
into (or operating too close to) the mechanical stops. These stop screws are
used for calibration purposes only and are backed out of the valve operating
range before shipment to the customer.

Procedure for EM35 Actuator Field Replacement

The EM35 actuator may be replaced in the field without affecting the calibration
of the valve/actuator assembly. This procedure describes the steps necessary to
perform an actuator replacement in the field.

Required Tools: 3/16” ball hex driver, 6” long, 3/8” drive

5/16” ball hex driver, 6” long, 3/8” drive
3/8” drive ratchet
5/16” hex Allen wrench
3/8” drive torque wrench, capable of 33.2 Nxm (24.5 lb-ft)

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EM35MR1/3103 Gas Valve Manual 40185

Procedure
1. Locate the coupling assembly between the 3103 gas valve and the EM35
actuator; it can be viewed through the long vertical slot in the adapter
housing.

Adapter Housing
EM35 Mounting Screws

EM35 Actuator

Coupling Access Slot

2. Using the 3/16” ball hex driver, loosen the socket head cap screw that
clamps the coupling assembly to the EM35 output shaft. Do not loosen the
clamp screw that mounts the coupling assembly to the valve shaft.

Coupling Clamp Screw, Actuator Removed

14 Woodward
Manual 40185 EM35MR1/3103 Gas Valve
3. Using the 5/16” Allen wrench, remove the five socket head cap screws and
lock washers that mount the EM35 actuator to the adapter housing. Remove
the EM35 actuator from the assembly.

4. Before installing the new EM35 actuator, properly orient the unit so the two
lining pins for the actuator match up with the corresponding holes in the
adapter housing. If necessary, rotate the shaft of the EM35 motor by hand to
properly orient the splines up with those of the coupling assembly.

When everything is in position, first slip the actuator shaft into the coupling
assembly, then line up the pins of the actuator with the adjacent holes in the
adapter housing. The actuator should mate up without any binding or use of
significant force.

5. Once the actuator is in proper position, re-install the five socket head cap
screws and lock washers removed in step 3. Torque the bolts to 33.2 Nxm
(24.5 lb-ft).

6. Using the 3/16” long ball hex driver and torque wrench, tighten the socket
head cap screw on the coupling at the EM35 output shaft. Torque to 9.3
Nxm (82 lb-in).

7. Reconnect field wiring to EM35 actuator terminal blocks.

8. Perform valve stroking procedure, verifying the valve can be stroked from
the minimum to maximum stop.

Woodward 15
EM35MR1/3103 Gas Valve Manual 40185

Chapter 6.
Valve Sizing—Non-DLE Applications

Determination of Effective Area

In order to choose the proper size of valve for an application, the effective area
required to meet your maximum flow requirement must first be determined. The
effective area is determined using the following equations.

K
K 1
2
R7( K )
1 K

P2 FLOW
If R7 Effective_Area
P1 2 1 K
K K
K . Sg P2 P2
3955.289 . P1 . .
( K 1 ).T.Z P1 P1

P2 FLOW
If < R7 Effective_Area
P1 2 1 K
K . Sg . R7 K K
3955.289 . P1 . R7
( K 1 ).T.Z

Where:
• P1 = Valve inlet pressure (psia)
• P2 = Valve discharge pressure (psia)
• K = Ratio of specific heats for the gas
(1.300 typical for standard natural gas at 60 °F)
• Sg = Specific gravity relative to air for the gas
(0.60 typical for standard natural gas)
• Flow = Valve metered flow (lb/h)
• T = Temperature of the gas (Deg Rankine)
(Deg R = Deg F + 459.7)
• Z = Gas Compressibility Factor
(essentially 1 for most applications—see the following graph)

NOTE
The valve size selected should be sized to be adequate for worst-case flow
conditions. This would be minimum P1, maximum P2, maximum flow, and
maximum temperature.

16 Woodward
Manual 40185 EM35MR1/3103 Gas Valve

Valve Sizing and the Effective Area Tables

Once the effective area has been determined, move to the effective area tables
later in this chapter. The effective area table has % valve travel, demand mA,
and valve angle listed in the first three columns. The following ten columns list
the valve effective area for pressure ratios (P2/P1) from 0.05 to 0.95 respectively.
To pick the proper size valve for an application, move to the sheet that has a
value for effective area greater than or equal to that determined above in the 100
percent travel row for the applicable pressure ratio column.

NOTE
Woodward recommends that no less than 60% valve travel be used for the
full control range. Using less than that could cause instability problems as
the system attempts to control at very low increments of travel.

Woodward 17
EM35MR1/3103 Gas Valve Manual 40185

Determining the Demand Required to Achieve

Specific Flows
To determine demand values necessary to achieve a specific flow at end or
intermediate points once the valve size is set, is very similar to the process used
for sizing the valve. First, determine the necessary valve effective area for the
flow point. Interpolate between pressure ratios and demand columns to
determine at what percent/mA/valve angle the flow will be achieved.

Notes on the Valve Sizing and Application Program

The algorithm used for sizing and demand value determination used in the
standard valve application programs available for the 3103 is basically the same
as that described above. However, the program makes use of a valve inlet
pressure compensation algorithm that enhances the accuracy of the calculation.
This compensation scheme is not easily implemented in a manual system as
described here. Therefore, the demand values determined using the methods
described here will be slightly different from those determined using the
application programs. Since this difference is small, the use of the application
program is not absolutely necessary for the sizing/application of standard valves.

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Manual 40185 EM35MR1/3103 Gas Valve
3103 1.0 in² port, Effective Area Table

Valve angle = Resolver Feedback Angle – Resolve Offset Angle

Resolver Offset Angle = ~20 degrees
4 mA = 0° valve angle = 0% valve position = ~20 resolver angle
min stop = –2 degrees valve angle
max stop = 62 degrees valve angle

Woodward 19
EM35MR1/3103 Gas Valve Manual 40185
3103 1.5 in² port, Effective Area Table

Valve angle = Resolver Feedback Angle – Resolve Offset Angle

Resolver Offset Angle = ~20 degrees
4 mA = 0° valve angle = 0% valve position = ~20 resolver angle
min stop = –2 degrees valve angle
max stop = 62 degrees valve angle

20 Woodward
Manual 40185 EM35MR1/3103 Gas Valve
3103 2.0 in² port, Effective Area Table

Valve angle = Resolver Feedback Angle – Resolve Offset Angle

Resolver Offset Angle = ~20 degrees
4 mA = 0° valve angle = 0% valve position = ~20 resolver angle
min stop = –2 degrees valve angle
max stop = 62 degrees valve angle

Woodward 21
EM35MR1/3103 Gas Valve Manual 40185

Chapter 7.
Maintenance

There are no critical maintenance items in the EM35MR1/3103 gas valve

assemblies, such as filters that should be changed, etc. The valve assembly
should be visually inspected, in accordance with your specific maintenance
schedule. Each site must determine the appropriate schedule based on the
severity of the service conditions. Inspect for dirt, grease, dust, or other buildup in
the areas of moving parts or joints. Clean environmentally originated buildup from
the unit; if cleaning solution is used, verify that it is compatible with the Viton® *
and Teflon® * valve seal materials. If any buildup appears to have originated from
within the valve, return the valve to Woodward for service (see Chapter 8).

*—Viton is a registered trademark of DuPont Performance Elastomers.

Teflon is a registered trademark of the DuPont Company.

22 Woodward
Manual 40185 EM35MR1/3103 Gas Valve

Chapter 8.
Service Options

Product Service Options

The following factory options are available for servicing Woodward equipment,
based on the standard Woodward Product and Service Warranty (5-01-1205)
that is in effect at the time the product is purchased from Woodward or the
service is performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture

If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of
action you wish to pursue based on the available services listed in this
section.

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 also a flat rate structured program and includes the full
standard Woodward product warranty (Woodward Product and Service Warranty
5-01-1205).

This option allows you to call 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 Woodward facility as explained below (see “Returning Equipment
for Repair” later in this chapter).

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 to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]

Return Shipment Authorization Label. To ensure prompt receipt of the core,

and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacement/Exchange unit that leaves
Woodward. The core should be repackaged and the return authorization label
affixed to the outside of the package. Without the authorization label, receipt of
the returned core could be delayed and cause additional charges to be applied.

Woodward 23
EM35MR1/3103 Gas Valve Manual 40185

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 to Woodward for
repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
• 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.

CAUTION—ELECTROSTATIC DISCHARGE
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.

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.

24 Woodward
Manual 40185 EM35MR1/3103 Gas Valve

Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [1 (800) 523-2831 in North America or
+1 (970) 482-5811]. They will help expedite the processing of your order through
our distributors or local service facility. To expedite the repair process, contact
Woodward in advance to obtain a Return Authorization Number, and arrange for
issue of a purchase order for the item(s) to be repaired. No work can be started
until a purchase order is received.

NOTE
We highly recommend that you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
1 (800) 523-2831 in North America or +1 (970) 482-5811 for instructions and
for a Return Authorization Number.

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.

How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA

Telephone—+1 (970) 482-5811 (24 hours a day)

Toll-free Phone (in North America)—1 (800) 523-2831
Fax—+1 (970) 498-3058

For assistance outside North America, call one of the following international
Woodward facilities to obtain the address and phone number of the facility
nearest your location where you will be able to get information and service.

Facility Phone Number

Brazil +55 (19) 3708 4800
India +91 (129) 4097100
Japan +81 (476) 93-4661
The Netherlands +31 (23) 5661111

You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodward’s website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility.

Woodward 25
EM35MR1/3103 Gas Valve Manual 40185

Engineering Services
Woodward Industrial Controls Engineering Services offers the following after-
sales support for Woodward products. For these services, you can contact us by
telephone, by email, or through the Woodward website.

• Technical Support
• Product Training
• Field Service

Contact information:
Telephone—+1 (970) 482-5811
Toll-free Phone (in North America)—1 (800) 523-2831
Email—icinfo@woodward.com
Website—www.woodward.com

Technical Support is available through our many worldwide locations or our

authorized distributors, depending upon the product. This service can assist you
with technical questions or problem solving during normal business hours.
Emergency assistance is also available during non-business hours by phoning
our toll-free number and stating the urgency of your problem. For technical
support, please contact us via telephone, email us, or use our website and
reference Customer Services and then Technical Support.

Product Training is available at many of our worldwide locations (standard

classes). 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. For information concerning training, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Product Training.

Field Service engineering on-site support is available, depending on the product

and location, from one of our many worldwide locations or from one of our
authorized 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 field service engineering assistance, please contact us via
telephone, email us, or use our website and reference Customer Services and
then Technical Support.

26 Woodward
 Manual 40185 EM35MR1/3103 Gas Valve

Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:

General
Your Name
Site Location
Phone Number
Fax Number

Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application

Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number

Woodward Part Number and Revision Letter

Control Description or Governor Type

Serial Number
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 27
EM35MR1/3103 Gas Valve Manual 40185

28 Woodward
 EM35MR1/3103 Specifications
The EM35MR1 electric actuator was designed for the positioning of Woodward gas and
liquid valves equipped with resolver feedback. The actuator requires a final driver for
driving the motor and for closed loop control.

The EM35MR1 actuator uses a brushless dc motor with a reducing planetary gearhead.
The motor is designed with Samarium Cobalt permanent magnets bonded to the rotor
element and all stator windings are completely sealed. Rotor position sensing is
performed by the field director unit integral with the motor. This inductive device requires
excitation and demodulation within the electronic motor controller.

Mechanical
Output shaft rotation 60° (Rotation limited by valve stops)
Actuator/valve coupling Direct Coupling
Torque constant 1.8 Nxm/A (16 lb-in/A)
Continuous output torque ±25 Nxm (±220 lb-in) maximum
Peak output torque ±62 Nxm (±552 lb-in) minimum
Clutch breakaway torque ±68 Nxm (±600 lb-in)
Valve gas connection 2" 600# ANSI B16.5 (51 mm, 2669 N)
Gas flow 23 to 18 144 kg/h (50 to 40 000 lb/h) natural gas
Gas pressure 0 to 6205 kPa (0 to 900 psia)
0 to 4964 kPa (0 to 720 psia) (restriction for CE Marking)
Minimum pressure differential Non-DLE: 172 kPa (25 psid)
DLE: : 345 kPa (50 psid)

Electrical
Power input 28 Vdc nominal, 18–32 Vdc operating, 15 A continuous,
37 A peak for 50 ms

Performance
Slew time (50 deg) 150 ms open, 80 ms close at 28 V (100 ms close for 137:1
gear ratio) where slew time = valve travel ÷ max slew rate
Bandwidth >5 Hz
Position accuracy ±0.50° analog, ±6 arc min RSS (root sum squared) digital

Environmental
Ambient Temperature and
Fuel Temperature –40 to +149 °C (–40 to +300 °F)
Ambient Temperature and
Fuel Temperature
(Restriction for CE Marking) –29 to +149 °C (–20 to +300 °F)
Vibration US MIL-STD-810C Method 514.2, Category b.1, Table
514.2-II, Figure 514.2 curve j (5 g)
Shock US MIL-STD-810C, Method 516.2, Figure 516.2-1, 20g 11
ms sawtooth
 We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please include the manual number from the front cover of this publication.

PO Box 1519, Fort Collins CO 80522-1519, USA

1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058
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.

2008/8/Fort Collins