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Mie Sczestone Work Instructions SPV25 to Woodward Valve Upgrade Kit Installation — Model C60 MicroTurbine Purpose and Scope This document describes the removal of the SPV25, related LIP components and ‘subsequent installation of the Woodward valve upgrade kit. See Figure 1 UFCB Controller {chown wlth Proceure Transducer) (sros47 Figure 1. Woodward Upgrade Kit Components Guidelines This document presents information sufficient to allow an Authorized Service Provider (ASP) to properly replace the Woodward valve and related components. Conduct maintenance in a clean, well-lighted area using normal shop tooling to avoid damage to delicate components. Retain all parts removed for use at assembly, unless otherwise specified, Discard all parts as noted in this document. 440128-001 Rev A (January 2006) je 1 of i Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation Safety Precautions ‘Observe and adhere to the Safety Precautions listed below when servicing your MicroTurbine. Read and become familiar with the General Safety Precautions and Instructions contained within the MicroTurbine Users Manual (400001). Before servicing: a a ‘Check to ensure that the inlet fuel supply is SHUT OFF and detached from the NicroTurbine. ‘Always check to ensure that your MicroTurbine is disconnected from the utility Isolate and lock out the utility (if applicable), Isolate and lock out any ther sources of power to the MicroTurbine. For example, connections to the solid state relays in the MicroTurbine ‘Communications Bay. ‘Open the Stand Alone battery circuit breaker, lock it in the OFF position, and then unplug the battery cable. Ensure above power sources have been tured off and the unit has been disconnected for at least five minutes to reduce the risk of electrical shook. Use a voltmeter to verify that no voltage is present on the DC bus. Never work on energized equipment Observe all safety precautions to prevent injury or death. 440128-001 Rev A (January 2006) Page 2 of 14 perpen Si te in ert ure etre te eet Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation Material Information The following parts comprise the Woodward Valve Retrofit Kit 610098-100. Part Number Nomenclature 519347-100 | UFCB Controller Assembly, Natural Gas 518348-100 | Woodward Valve Assembly, Natural Gas §19480-001 | Pressure Transducer 518908-002 | Filter, 12, Inline, Flaretess Tube Fitting 519345-100 | Tube Assembly, -8 Woodward Valve Qui-Manifold 519338-001 | Tube, -12, Shutoff ta Woodward Valve Inlet 519346-100 | Tube Assembly, -6, Fuel Vent Out 519937-001 | Tube, 12, Inlet to Shutoff §19244-100 | Shutoff Assembly with Bracket 519341-001_| Bracket, Shutoff, Woodward Valve 518342-001 | Bracket, Shutoff, Inlet Tube §19243-001 | Bracket, Anti-rotation J 512294-010 | Fitting. Bulkhead, -12 Tube x 1/2" NPT Male =|+|+]=|=|=|-/=]-|3/3)-]=|=|=/=]8]8]-||-|=|=|-|»]-]-|-|- |+|-|-|-|8 518472.001 _| Filling. Male Connector, -12 Tube to ~12 Tube, NPT 518471-001 | Fitting, Male Adapter, -12 Tube to 12 NPT, M, SS 514037-063 | Bolt, Hex Head, MB x 16, Zinc 507750-001_| Washer, Flat 1/4.inch, 1/16 thickness, 1/2 GD 507874-001 | Washer. Splitock, 1/4 zine-platod 508430-013 | Nut Hex, KEPS, Ext-lack washer 514926-001 | Fitting. Bulkhead, -6 Tube to 1/4 NPT 516983-100 | CABA, C200, FCM Fuel Valve §18875-100 | CABA, Ext C60 UFCB to Manifold 507274-002 _| Sealant, Pipe Tape, Natural Gas 506711-001 _| Locker, Thread (Locktite 242) 508106-001 | Washer, Flat, 1-inch (1.082 ID. 2.6 OD), Zine 514016-001 | Label, High Pressure, NG 510622.002 _| Seal, 37°, Conical -8, Crush Washer, NI §10622-003 | Seal, 37°, Conical -€, Crush Washer, NI 513808-001 | Filter, Vent, % NPT, 4 cim 513592.008 | Nut, Tube, BZ, -8. CPI Fig, SS §13592-012 _| Nut, Tube, BZ, -12, CPIFig. SS 513531-008 | Ferrule, Tube, TZ. -8. CPI Fig, SS 513531-012 _| Ferrule, Tube, TZ, -12, CPIFig, SS ‘440128-001 Reev A (lanuary 2008) Poge3 of 14 ‘Tripartite Cn ty arg fone el en at ed Sanna apie samen Sas ears ean outa Sanh ea la Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation Recommended Tools Use the Capstone’s Recommended Tools (400003) or equivalent to perform procedures listed in this document. Additional tools/materials required: a DooOoOoDDOoOeD 10-mmm socket and open-ended wrench 7i8-inch open-ended wrench TI6-inch open-ended wrench 14/16-inch open-ended wrench 41/4 -inch open-ended wrench 13/16 -inch open-ended wrench 41 1/8 -inch open-ended wrench Teflon pipe tape, U/L rated (No. 2598, Lab 501 or equivalent) Gas leak detector (Snoop, soapy water, gas sniffer) Torque wrench, adjustable, 0 — 980 Ibs Hand Drill and bit set, commercial 440128-001 Rev A (January 2006) Page dof 14 perpen Sei te in ert ure etre te ent Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation Removal and Installation Procedure 1. Remove MicroTurbine side panels using a 10-mm socket wrench. 2. Unplug all of manifold/shutoff and intra hamesses connecting the SPV25 to the shutoff valve. See Figure 2. Outlet Fitting Shutoff Valve §) —— SPV25 Bolts (2) sPv2s sPv2s Inlet Fiting sPv2s Mounting Botts (1of 4 shown) Figure 2. SPV25 Removal (Underside shown) SPV25 Removal (see 440028-001 for more details) NOTE — Remove fitings siowly to reduce impact from line pressurization. 1. Open the inlet fiting on the SPV25 side of the tube using a 7/8-inch wrench. Use a second 7/8-inch wrench to support the fitting in the SPV25 housing. 2. Open the outlet fitting on the shutoff valve side of the tube connecting to the SPV25 using a 7/8-inch wrench. Support the insert using the 1 1/16-inch wrench. 3. Remove the inlet tube. Tube will not be retained and may be discarded. 4. Open the outiet fitting to the SPV25 using a 7/G-inch wrench. Use the 1- inch wrench to support the fing in the SPV25 housing. This line may be pressurized: therefore, release pressure siowly to prevent damage to the fitting 5. Remove the outlet tube. Tube will not be retained and may be discarded Remove two 7/16-inch bolts securing the SPV25 valve to the bracket 7. Remove the SPV25 assembly by detaching four 7/16-inch mounting bolts from the upper side of the fuel plate. 440128-001 Rev A (January 2006) Page Sof 14 perpen Sie in ert ure etre te eet Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation ‘Shutoff Valve Removal (see 440032-001 for more details) 1. Remove the tube on the inlet side of the shutoff valve using a 7/8-inch wrench, and an 111/16-inch backup wrench. See Figure 3. Detach the outlet side of the filter tube using a 7/8-inch wrench, and a 1 1/4-inch backup wreneh. Tube will not be reused and may be discarded. 2 Inlet Side of Shutoff Valve Filter Figure 3. Shutoff Valve Tube Removal 3. Remove the ground wire using a 7/16-inch socket. 4. Remove the shutoff valve by detaching two 7/16-inch mounting bolts. Reiain the shutoff valve fer future installation. See Figure 4. Shutoff Valve Outlet Side of Fuel Inlet Shutoff Valve Fitter aerviees ‘Ground Wire Line Figure 4. Shutoff Valve Removal Filter Element Removal 1. Remove the service line trom the fuel inlet fiter using an 11/16-inch wrench on the tube and a 1 1/d-inch wrench as backup on the fitting. 2. Remove the filter from the fuel plate by detaching two 7/16-inch bolts. 1440128-001 Rev A (January 2006) Poge6 of 14 ‘Toga nT Cn ey arr fone tel en at ed Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation Woodward Valve Inst 1. Mark and dri 10 holes on top of the MicroTurbine turbine deck to mount Woodward components (see Figure 5 and Appendix A for more details). Hole Location (of 10:shown} Figure 5. Hole Drilling Locations (Top View of Turbine Deck shown} 2. Drill additional holes on lower rear panel to accommodate the vent valve and anti-rotation valve (see Appendix B). Install vent tube fitfing (514928). Vent Tube Fitting (514928) Figure 6. Vent Valve Installation 3. Disconnect the TET hamess from the underside of turbine deck to allow access to Woodward component installation. See Figure 7. Figure 7. Disconnect TET Switch 1440128-001 Rev A (January 2006) Poge7 of 14 ‘Tigran Tt Cp ey arrose en at edhe Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation 4. Secure Woodward valve with 10mm bolts and attaching hardware, See Figure 6. Woodward Valve Mounting Hardware Bolt (514037-063) — Qty 4 ‘Washer (507750-001) - Qty 4 ‘Washer (507874-001) - Qty. Figure 8. Securing the Woodward Valve 5. Mount the UFCB controller (519347) with mounting hardware shown to the underside of the turbine deck. See Figure 9. UFCE Controller (519347) Mounting Hardware Bolt (514037-063) ~ Qty 4 ‘Washer (507750-001) — Qty 4 ‘Washer (507874-001) — Qity 4 Figure 9. Mount Controller Assembly 6. Secure UFCB controller from the top of the enclosure with four 10mm bolts. See Figure 10, Figure 10. ‘440128-001 Rev A (lanuary 2008) Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation 7. Install upper shutoff vaive (619344) and mount as shown with bolts (514037), washers (507750) and nuts (508430). ‘See Figure 11 Upper Shutoff Valve (519344) Mounting Bracket ‘Mounting Hardware Bolt (514037-063)— Qty 4 Washer (507750-001)— Qty 4 Nut (508430-013) - Qty 4 Figure 11. Upper Shutoff Valve 8. Assemble the anti-rotation bracket (519343) to the inlet fuel line and install on the rear of the MicroTurbine with mounting hardware. See Figure 12. Anti-rotation Bracket Bulkhead Fiting 12294) ba Washer (507750-001) — Qty 2 Nut (£08430-013)— Qty 2 Figure 12. Anti-rotation Plate 9. Install the bracket (519342) on the lower shutoff valve (519344) and install into the bulkhead on the rear of the MicroTurbine. Mount as shown with Shutoff Valve Lower Bracket (519342) Fitting (519471) — Qty 1 F 12 Formule (513531-012) —Aty 4 Bhitoft ‘ +12 Nut (513592-012} — Qty 1 Figure 13. Lower Shutoff Valve 440128-001 Rev A (January 2006) Page 9 of 1: perpen Sie in ert ure eer lg el eet Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation 10. Attach the tube (519337) to the shutoff valve and secure fitting with a 1 1/8- inch wrench. Attach the ground wire to the bracket. See Figure 14. Lower Shutoff ‘Valve Tube Fitting - "i (519337) (519472) Figure 14. Lower Shutoff Valve Tube Installation 111. Attach the other end of the tube (519337) ta the upper shutoff valve with a 1 1/8-inch wrench, and a 1 3/16-inch backup wrench on the fitting. Upper Shutoff ‘Valve Tube (519337) Figure 15. Upper Shutoff Valve Tube Installation 12.\nsert the in-line fiter (518908) into the valve as shown. Install tube (519338) from the shutoff valve to the Woodward valve, and secure with a 1 1/8-ineh wrench, and 1 3/16-inch backup on the fitting. See Figure 16. Shutoff-to-Woodward Install Inline Valve Tube (519338) Filter (518508) Inside Fitting (not shown) Figure 16. Shutoff-to-Woodward Valve Tube Installation 440128-001 Rev A (January 2006) Page 10 of 14 perpen Sie in ert ure etre el eat Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation 13. Install the hamess connection to the lower shutoff valve. See Figure 17. Shutoff Valve Hames Figure 17. Lower Shutoff Valve Harness Installation 14, Install the harness connection to the upper shutoff valve. See Figure 18. Shutoff Valve Hames Figure 18. Upper Shutoff Valve Harness Installation 16. Install all connector hamesses as shown on the UFCB controller. See Figure 19. Pressure Transducer Intra Hames Manae Manifold Shutoff Harness (518875) Valve Harness (516993), UFCB Controller Figure 19. Woodward Valve Harnesses Installation 1440128-001 Rev A (January 2006) Page 11 af 14 ‘Tigran noi Cp hey renee fe Sd ot ah Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation 16. Install the UFCB hamess on the Woodward valve. See Figure 20. Fee Harness Figure 20. UFCB Harness Installation ‘17. Install one end of the fue! manifold tube (519345) to the Woodward valve with an *-8" crush washer (510622-002) and seoure with a 7/&-inch wrench. See Figure 21 Fuel Manifold Tube (519345) “9” Crush Washer (510622-902) Figure 21. Fuel Manifold Tube Installation (Woodward Valve) 16. Secure tube connections on the fuel manifold end with a 7/8-inch wrench Fuel Manifold Tube (519345) 8 Ferrule (513531-008) — Qty 1 -@ Nut (513532-008)— Qty 1 Figure 22. Fuel Manifold Tube Con 440128-001 Rev A (January 2006) Page 12.0f 14 perpen Sie in ert ure etre te ent Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation 19. Install one end of the vent valve (519346) to the Woodward valve with a *.6" crush washer (510622-003) and secure with an 11/16-inch wrench. See Figure 23. 7 “.6" Crush Washer (610622-003) Figure 23. Vent Tube Installation (Woodward Valve) 20. Install the other end of the vent tube (519346) to the lower rear panel with an 11/16-inch wrench. See Figure 24, Vent Tube (519346) Figure 24. Vent Tube Installation (Lower Frame) 21. Place a vent filter (513808) into the (female) NPT fitting on the outside of the rear panel 22. Reattach the TET connector hamess. 23. Install label (514016) to the rear of the MicroTurbine. 24. Tum power an, open the fuel supply and initiate an engine start 25. Check fittings for leaks using a leak detector (e.9. Snoop, soapy water, or gas sniffer). 26. Test system for proper operation as detailed in the MicroTurbine User's Manual (400001). 440128-001 Rev A (January 2006) Page 13 of perpen Sie in ert ure eet el eet Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation ity It is the responsibility of Capstone to make these procedures available to the Authorized Service Providers so they can successfully complete this task. It is the responsibility of the Authorized Service Providers to read this document, understand its contents, and effectively complete the replacement procedures. Itis the responsiblity of the Authorized Service Provider to provide Capstone with a Field Service Report when the replacement task is completed. Responsi Notifying Capstone Customer Service Upon completion of the installation of the Woodward valve and related components, complete a Commissioning Checklist, and submit the paperwork to Capstone Technical Support. If you have additional questions, please contact: Capstone Technical Sui Toll Free Telephone: (877) 282-8966 Service Telephone: (818) 407-3600 Facsimile: (818) 734-1080 E-mail: service@capstoneturbine.com Capstone Technical Support - Japan Service Telephone: (818) 407-3700 Facsimile: (818) 734-1080 E-mail: servicejapan @capstoneturbine.com 440128-001 Rev A (January 2006) Page 14 of peptone Sie in ert ure eer lg el ent Capstone Turbine Corporation » 21211 Nordhoff Street » Chatsworth « GA 91311 = USA ‘Work instructions: SPV to Woodward Valve RetrofitKit installation Appendix A - Drilling Hole Locations on MicroTurbine Frame = 26.623 + 28.673 ——____~ 2x R625 5.587 42.077 “4 Foes. 2x 925+ = tant | -—— 12.836 @.000—b 7 le 14.086 4 Figure A-1, Drilling Locations on Turbine Deck (View from Bottom) Legend (Hole Locations) W- Woodward Valve - UFCB Controller Z- Shutoff valve 440128-001 Rev A (January 2006) Page A-t perpen Sei ee i er are eer li te eens Capstone Turbine Corporation » 21211 Nordhoff Street « Chatsworth « CA.91311 + USA Work instructions: SPV to Woodward Valve Retroft Kit Installation Appendix B - Drilling Hole Locations on MicroTurbine Lower Right Rear Figure B-1. Drilling Locations on Lower Right Rear of MicroTurbine Legend (Hole Locations): X— Anti-Rotation Valve 440128-001 Rev A (January 2006) Page B-1 ‘eer Gre tt mre nf tne tnt Pap eect ee

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