ProAct™ III / IV Electric Powered Actuator and Driver
Contents
1. 9 Hz 4 20 mA Output Models Units which provide a 4 20 mA output proportional to actuator position have two additional 25 turn potentiometers Position Span and Position Offset These potentiometers adjust the 4 20 mA output to correspond to minimum and maximum positions of the actuator The Position Offset adjusts the output at minimum position to be 4 mA The Position Span adjusts how much the output changes with a given actuator position change and is used to adjust the maximum output current The adjustments are interrelated and may need to be repeated until the desired output is achieved Actuator Position Signal The feedback device is located on the closed shaft of the actuator The device is a rotary transducer which changes resistance proportional to the location of the shaft The device is a non contacting unit thereby eliminating most wear problems The feedback voltage is approximately 2 Vdc at 0 and 3 Vdc at 75 measured from 0 to Actuator The rotary design of the ProAct actuators gives 75 degrees of shaft rotation to position fuel controls The actuators apply torque in both directions Torque is proportional to the current supplied to the actuator by the driver The actuator uses sealed bearings eliminating the need for maintenance The feedback mechanism attaches to the end of the rotor not being used to control the engine The device is enclosed in a Ryton housing and is sealed against the elements Avoid2. C 40 to 158 F Mount the driver in a location with space for adjustment and wiring access Do not expose the driver to sources of radiant heat such as exhaust manifolds or turbochargers Mount the driver close enough to the actuator and battery to meet the wire length requirements see wiring instructions in this chapter The driver will generate some heat so surfaces must be open to normal air movement No special ventilation is required The driver must be bolted to a heat sink of a minimum 0 4 m 4 ft of 3 mm 1 8 inch mild steel Ideally the driver should be mounted flush to the metal side of a control cabinet protected from the weather and high humidity and close to the engine being controlled Do not install the driver directly on the engine The location should provide protection from high voltage or high current devices or devices which produce electromagnetic interference After initial adjustments are completed access to the driver will not be required for normal engine operation Actuator Installation Thermal The actuators are designed for installation on the engine The actuators will generate heat especially when stalled or during other conditions requiring maximum torque output Maximum operating temperature for either the ProAct Ill or ProAct IV actuator is 100 C 212 F The installer must consider the heat conductivity of the installation bracket and the operating temperature of the ultimate heat
3. ProAct Ill MS connector CW to max ProAct Ill conduit CW to max ProAct III MS connector CCW to max ProAct III conduit CCW to max ProAct IV MS connector CW to max ProAct IV conduit CW to max ProAct IV MS connector CCW to max ProAct IV conduit CCW to max 40 to 70 C 40 to 158 F 55 to 105 C 67 to 221 F 95 at 38 C US MIL STD 810C Method 507 1 Procedure II SAE J1211 Paragraph 4 2 3 US MIL STD 810C Method 516 2 Proc Ill 20 to 32 Vdc 24 Vdc nominal 10 A sustained 20 A available for two seconds 40 to 100 C 40 to 212 F 55 to 125 C 67 to 257 F US MIL STD 810C Method 516 2 Proc IV US MIL STD 810C Method 514 2 Proc VIII 0 625 36 serrated ProAct III 0 750 48 serrated ProAct IV ProAct Ill Actuator is 0 027 in lb sec ProAct IV Actuator is 0 058 in Ib sec 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 MW WOODWARD PO Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 e 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 e
4. on the board 16 Woodward Manual 04127 ProAct III IV Actuator Driver Figure 3 5 ProAct Driver Adjustment Locations Actuator Travel The driver s span and offset adjustments normally don t need to be changed unless you experience difficulty getting the actuator to travel full stroke The following graphs define the relationship between command signal 0 200 mA or 4 20 mA and actuator position If the characteristic falls outside of the tolerance limits adjust span and offset as required with the goal to get the characteristic midway between the tolerance limits To set up the driver and actuator power up the system with the actuator disconnected from the linkage but with the inertia disk in place DO NOT START THE ENGINE AT THIS TIME Vary the current into the mA input to the driver and observe actuator angle Adjust span and offset to achieve the desired relationship see Figure 3 6 Failure to make this adjustment correctly may result in the inability to shut off fuel or the inability to reach full fuel position After this adjustment is made re install linkage coupling etc to the engine This procedure must be repeated whenever the actuator or driver is changed The Offset and Range pots are both located on the printed circuit board inside the driver box The Offset and Range pots are each 25 turn Both turn clockwise to increase the position of the actuator output for a given input to the driver See Chapter 2 for
5. Driver Manual 04127 WVH 11 27 76 Z60 Lvo SISIHINAHVA N NI 1 OFL H1 YVIINIS YO IGIIT 14 38 YIN SLVIdaNVN 3lVId 1o Ja I 2016 3HL13 HJONVHIXA IVAH NOI JILVAHIS Sr N Fl LI LI 10 Liv A INVId OL DI SHLON37 Figure 1 3 ProAct IV Actuator Outline Drawing Woodward ProAct III IV Actuator Driver Manual 04127 l l A HIT 18 2 Gs l 24 PPL l l RAY i GR A A l l 1 BLUE WHITE l i t CONTROL l WHITE AI JR OUTPUT l YRIVE l AA OH ESS RED 3N ei n TUAT l l Se Fl LAN fel DBACI f i pu Lo Wan Ee l l 1 l l gt Bo NO PES Se a CONDUIT CONNECTOR TUAT 41 069a J4 skw NOTE 1 Mating connectors J1 5416 460 J2 5416 461 J3 203 889 NOTE 2 Shielded wires to be twisted pairs with shield grounded at driver end only NOTE 3 8 6 or 4 mm 8 10 or 12 AWG stranded wire Must be as short as possible Maximum actuator wire lengths are shown on page 12 Figure 1 4 Plant Wiring Diagram 6 Woodward Manual 04127 ProAct III IV Actuator Driver Chapter 2 Description of Operation Introduction The P
6. pressure washing the actuator An inertia disc is installed on the actuator output shaft The disc is necessary for stable actuator operation with light low friction linkages Do not remove the disc see Figures 2 2 and 2 3 8 Woodward Manual 04127 ProAct III IV Actuator Driver Paka Ng N S N X E N fl 7 7 7 7 i gt 7 WA f NN 1 1 Figure 2 2 ProAct Ill Actuator Cross Section MS connector plug shown conduit version has conduit connector Woodward 9 ProAct III IV Actuator Driver Manual 04127 AS 2 9 in u u 3 VA U 4 7 4 VA u Ge 7 H u VA u l VA u Figure 2 3 ProAct IV Actuator Cross Section MS connector plug shown conduit version has conduit connector 10 Woodward Manual 04127 ProAct III IV Actuator Driver Chapter 3 Installation SSS aaa Driver Installation Unpacking Be careful when unpacking the electronic driver Check the driver for signs of damage such as bent or dented panels scratches and loose or broken parts Notify the shipper and Woodward if damage is found Mounting The driver box is designed to operate within a temperature range of 40 to 70
7. speed control Low friction long wearing rod ends are available from Woodward The link connecting the actuator lever to the fuel control lever must be short and stiff enough to prevent flexing when the engine is running Actuator levers are available from Woodward which allow adjustment of the rod end location with respect to the center of the actuator shaft The lever used must have a 0 625 36 serration to fit on the ProAct Ill actuator or 0 750 48 serration to fit on the ProAct IV actuator Adjust the location of the rod end on the lever to achieve the desired rotation of the actuator shaft between minimum and maximum positions Use as much of the 75 rotation as possible at least 60 To increase the amount of rotation move the rod end closer to the actuator shaft or farther away from the shaft controlling fuel flow To decrease the amount of rotation used move the rod end farther from the actuator shaft or closer to the shaft controlling fuel flow Electrical Connections External wiring connections and shielding requirements for a typical control installation are shown in the plant wiring diagram see Figure 1 4 Use 8 6 or 4 mm 8 10 or 12 AWG wire throughout the ProAct circuit The total distance from the battery to the driver and from the driver to the actuator must not exceed the maximum wire length indicated in the following formula one half the battery wire length plus the actuator wire length must be less than or
8. 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 Woodward 23 ProAct III IV Actuator Driver Manual 04127 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 Numb
9. 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 22 Woodward Manual 04127 ProAct III IV Actuator Driver 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 e Technical Support e Product Training e 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
10. W wooDwarRD Installation and Operation Manual Up ProAct IIl IV Electric Powered Actuator and Driver Manual 04127B WARNING 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 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 CAUTION 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 Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts e 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 e Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards e Donot touch
11. d 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 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 e Donot touch any part of the PCB except the edges e Do not touch the electrical conductors the connectors or the components with conductive devices or with your hands e 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 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 Woodward ProAct III IV Actuator Driver Manual 04127 iv Woodward Manual 04127 ProAct III IV Actuator Driver Chapter 1 General Information SSS SS SS SS eee The ProAct Ill and ProAct IV drivers convert either a 0 200 mA or 4 20 mA control signal from a Woodward electronic control into a specific actuator position The ProAct drivers require a separa
12. ditions Manually stroke the fuel control linkage from stop to stop as if the actuator were moving it The linkage must move freely without friction and without backlash Lubricate or replace worn linkage or fuel control parts as required A light loading spring to minimum fuel is included in the actuator A positive shutdown is necessary in the event of a loss of power to the actuator driver CAUTION The actuator s maximum slew rate can place stress on fuel system stops and on the linkage between the actuator and the fuel system Maximum actuator speed is 900 degrees per second in both the increase and decrease fuel directions The Pro Act Ill actuator s Mass Moment of Inertia MMOI is 0 027 in Ib sec The ProAct IV actuator s MMOI is 0 058 in Ib sec The fuel system stops must be adequate to absorb this MMOI plus the inertia of the linkage without damage Woodward 13 ProAct III IV Actuator Driver Manual 04127 ProAct Ill actuator stops are designed to absorb 1 1 J 10 in Ib of kinetic energy with 3 degrees overtravel ProAct IV actuator stops are designed to absorb 2 3 J 20 in Ib of kinetic energy with 3 degrees of overtravel If the actuator travel stops are used the linkage must be designed to allow this 3 degree overrun Use good rod end connectors with as little free play as possible Select rod ends which will not become loose and which will wear well during the nearly constant movement associated with precise
13. equal to 12 2 m For example actuator wire length 4 mm battery wire length 4 mm Actuator wire lengths may be multiplied by 1 6 for 6 mm 10 AWG wire Actuator wire lengths may be multiplied by 2 5 for 8 mm 8 AWG wire Shielded Wiring All shielded cable must be twisted conductor pairs Do not attempt to tin the braided shield All signal lines should be shielded to prevent picking up stray signals from adjacent equipment Connect the shields to the correct pins on the driver connector or wiring Do not connect shields to the actuator ground Wire exposed beyond the shield should be as short as possible not exceeding 50 mm 2 inches The other end of the shields must be left open and insulated from any other conductor DO NOT run shielded signal wires along with other wires carrying large currents See Woodward application note 50532 EMI Control for Electronic Governing Systems for more information 14 Woodward Manual 04127 ProAct III IV Actuator Driver Where shielded cable is required cut the cable to the desired length and prepare the cable as instructed below 1 Strip outer insulation from BOTH ENDS exposing the braided or spiral wrapped shield DO NOT CUT THE SHIELD 2 Using a sharp pointed tool carefully spread the strands of the shield 3 Pull the inner conductor s out of the shield If the shield is the braided type twist it to prevent fraying 4 Remove 6 mm 1 4 inch of insulation from the
14. er 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 24 Woodward ProAct Ill IV Actuator Driver Specifications SES Driver Part Numbers 9905 384 9905 385 9905 386 9905 387 9905 388 9905 389 9905 390 9905 391 9905 392 9905 459 9905 460 9905 461 Model Ill conduit 4 20 mA input Model III conduit 0 200 mA input Model III MS connector 4 20 mA input Model Ill MS connector 0 200 mA input Model IV conduit 4 20 mA input Model IV conduit 0 200 mA input Model IV MS connector 4 20 mA input Model IV MS connector 0 200 mA input Model III MS connector 0 200 mA input Model Ill MS connector 4 20 mA input Model IV MS connector 0 200 mA input Model IV MS connector 4 20 mA input These four models have an additional 4 20 mA output which is proportional to actuator position Actuator Part Numbers 8405 009 8405 010 8405 011 8405 012 8405 013 8405 014 8405 015 8405 016 Driver Box Operating Temperature Range Storage Temperature Range Humidity Shock Power Supply Current Requirements Actuator Operating Temperature Range Storage Temperature Range Shock Vibration Output Shaft Mass Moment of Inertia
15. igure 2 3 ProAct IV Actuator Cross Gechon ss mmmemnnnnnnnznnenznznnnanznzzi 10 Figure 3 1 Diesel Engine Travel Giops nn nannn nn na 12 Figure 3 2 Use ProAct Travel Stops for Carburetors ss ss 12 Figure 3 3 Example of Actuator Bracket sm mnn nnnnnnnnnena 13 Figure 3 4 Wiring to Power Guppiy LL nn nnennnnnnananznnnnnnnnn ann nanna anna 16 Figure 3 5 ProAct Driver Adjustment Locations ena 17 Figure 3 6 Tolerance Limits in Driver Getup sse enennnnnnnznnnnna 18 Table 1 1 ProAct Actuator Specifications sea 1 Table 1 2 ProAct Driver Configurations nanna 1 Table 1 3 ProAct Accessories A 2 ii Woodward Manual 04127 ProAct III IV Actuator Driver 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 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 Keep plastic vinyl an
16. impact see Figure 3 2 The engine must always shut down when the actuator is at the minimum stop Actuator Bracket The actuator may be installed on a bracket which attaches to the base with four M8x1 25 0 312 18 screws with a minimum engagement of 16 mm 0 625 inch The actuator may be mounted in any attitude The actuator is weatherproof and resistant to the corrosive effects of water and salt water Avoid pressure washing near the shaft seals The ProAct Ill actuator weighs 11 kg 25 lbs and the ProAct IV actuator weighs 19 kg 42 Ibs The bracket and attaching hardware must be designed to hold the weight and to withstand the vibration associated with engine mounting The bracket must also be designed to provide a heat sink heat transfer from the actuator to the engine block Figure 3 3 provides an illustration of the mounting bracket 12 Woodward Manual 04127 ProAct III IV Actuator Driver Figure 3 3 Example of Actuator Bracket When mounting on the bottom of the actuator torque the attaching bolts to 17 to 18 N m 150 to 160 Ib in Linkage Proper design and installation of the linkage from the actuator to the engine is necessary if the unit is to give good control Do not remove the inertia disk from the output shaft It is necessary to achieve steady state control with low external inertia loads Make sure that the actuator has ample work capacity to control the fuel supply under maximum load con
17. inner conductors The shield must be considered as a separate circuit when wiring the system The shield must be carried through connectors without interruption 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 ProAct control system Power Supply Power supply output must be low impedance for example directly from batteries Run an insulated wire directly from the positive battery terminal and negative battery terminal to the correct connection on the driver see Figure 3 4 Run a second insulated wire directly from the negative terminal of the battery to the driver Neither of these connections needs to be shielded Run the power leads directly from the power source to the control DO NOT POWER OTHER DEVICES WITH LEADS COMMON TO THE CONTROL see Figure 3 4 For controls with MS type connector controls and actuators connect the positive line to terminal J1 A and negative common to terminal J1 D For controls with conduit fittings and wires controls and actuators connect the positive line to the grav white wire Connect the negative terminal to the gray wire If the power source is a battery be sure the system includes an a
18. lternator or other battery charging device When the engine is shut down the driver powers the actuator into the minimum stop If the battery charging system is off when the engine is shut down this will cause the battery to be drained In this case the power to the ProAct must be turned off with a switch or relay Any such switch or relay must be interlocking to prevent starting the engine when power to the actuator is shut off A WARNING Do not remove power from the driver for normal shutdown procedures All actuator position commands should come from the control unit through the driver to the actuator Engine overspeed is possible if power is removed from the driver while the engine is running A CAUTION To prevent possible damage to the control or poor control performance resulting from ground loop problems follow these instructions Woodward 15 Manual 04127 ProAct III IV Actuator Driver Figure 3 4 Wiring to Power Supply Driver Adjustments It is important to set up the ProAct driver in the order that follows See Figure 3 5 for the location of potentiometers on the driver box CAUTION Always hold onto the side of the control box with one hand while making an adjustment with the other hand This prevents possible static damage to parts Use an insulated screwdriver to make adjustments Extensive damage is possible if the high voltages present inside the box are shorted to elements
19. mail information for all locations is available on our website 04 9 F
20. ment 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 e 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 N CAUTION 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 e antistatic protective bags on all electronic modules e packing materials that will not damage the surface of the unit e atleast 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls e astrong tape around the outside of the carton for increased strength Woodward 21 ProAct III IV Actuator Driver Manual 04127 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
21. nnnnnennnennnznnnonzn 11 Driver Installations ika i d ie a a d edd EEN 11 Actuator Installation ss nn eaaa daadaa nn nn nna nn ana iraani 11 Actuator Bracken ia d a kaan ta ba a Ek A dele iad LA nG 12 GT 13 Electri al GONNE tjOMS ed cc ces ss RA GTA KA AA AA 14 Shielded WANING TEE 14 tee EE 15 Driver el E a NAAN NAA ee 16 emt reel TEE 17 CHAPTER 4 TROUBLESHOOTING cseccseeccceeeccuneceuseceeaeeecueeeeuseeeeaeeeaeenasees 19 Introducton NAA AKAE KA nn II Ennan annann Ennan nannan anena 19 Linkage and Actuator Stroke nanna ann rna 19 CHAPTER 5 SERVICE OPTIONS LLmnmennnnnnnnnnnnnnmnnnnn name nanna mnnnannnmnmnnnnmmnnnn na 20 Product Service Options nn 20 Returning Equipment for Repair 21 Replacement Parts AA 22 How to Contact VWoodward 22 Engineering Services nanna amar n ran nm nanna 23 Technical Aesisiance ena n nn nn nata n nn anna tran nn nnnn nn nnnzzzznananzzn 24 PROACT III IV ACTUATOR DRIVER SPECIFICATIONS LL nn ennunennnnenennnmennzmnna 25 Woodward ProAct III IV Actuator Driver Manual 04127 Illustrations and Tables Figure 1 1 ProAct Driver Outline Drawing nn nanna 3 Figure 1 2 ProAct Ill Actuator Outline Drawing L nn 4 Figure 1 3 ProAct IV Actuator Outline Drawing nanna 5 Figure 1 4 Plant Wiring Diagram nn nnannn nanna nanna tn 6 Figure 2 1 ProAct Ill and IV Functional Block Diagram sen 7 Figure 2 2 ProAct Ill Actuator Cross Section nem 9 F
22. o 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 20 Woodward Manual 04127 ProAct III IV Actuator Driver 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 Equip
23. 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 e the part number s XXXX XXXX that is on the enclosure nameplate e 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 91 129 230 7111 Japan 81 476 93 4661 The Netherlands 31 23
24. roAct control system functions by receiving a current signal from a Woodward electronic governor The system then sends a pulse width modulated PWM current 20 A to 20 A signal to the actuator modified by signals from a position feedback velocity and current sensor from the actuator see Figure 2 1 Le Oe Oa Oa Figure 2 1 ProAct Ill and IV Functional Block Diagram Electronic Circuits All circuits in the ProAct driver are solid state and are not serviceable in the field The printed circuit board is manufactured by Woodward to provide maximum tolerance to temperature and vibration Three potentiometers accessible when the cover of the driver box is removed provide all adjustments to the driver system Woodward 7 ProAct III IV Actuator Driver Manual 04127 A 25 turn potentiometer Offset adjusts the actuator position with a minimum input signal from the speed control A 25 turn pot Span adjusts how far the actuator travels when the speed control signal varies from minimum to maximum This pot adjusts the maximum position of the actuator The Span adjustment range is approximately 40 degrees to 75 degrees The Span and Offset adjustments are interrelated The adjustments may need to be repeated until the desired actuator travel is achieved A one turn pot ACT BANDWIDTH adjusts how quickly the actuator responds to a change in signal from the speed control bandwidth 2
25. sink to which the bracket will be attached Generally the heat transfer abilities of aluminum and low carbon steel are better than those of high carbon steel or stainless steel Uninhibited air flow over the heat exchanger fins on the side of the actuators will help control possible heat problems Keep the fins as clean as possible to improve heat transfer Do NOT paint the fins since this will reduce the heat transfer efficiency If operating temperature is a concern contact Woodward for more information Woodward 11 ProAct III IV Actuator Driver Manual 04127 Fuel Position Stops Diesel Stops Diesel installations will generally use the fuel system minimum and maximum position stops Diesel engine racks are normally designed to provide the minimum and maximum stops without binding The actuator s stops must not prevent the actuator from driving the fuel linkage to the minimum and maximum positions The linkage should be designed to use as much actuator travel as possible without preventing minimum and maximum fuel positions see Figure 3 1 Figure 3 1 Diesel Engine Travel Stops Figure 3 2 Use ProAct Travel Stops for Carburetors Gas Engine Stops Butterfly valves in carburetors will often bind if rotated too far toward minimum or maximum For this reason the stops in the actuator should be used at both minimum and maximum positions Note that the stops will allow up to 3 degrees of additional rotation in both directions during
26. tance 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 t
27. te electrical supply of 20 32 Vdc The supply must be capable of supplying a sustained 10 A and a peak 20 A for up to two seconds for both the ProAct Ill and ProAct IV drivers The ProAct Ill actuator provides up to 14 J 10 ft lb of work to move the fuel setting lever on the engine The ProAct IV actuator provides up to 27 J 20 ft lb of work The actuators rotate 75 degrees and they have position feedback Figures 1 1 through 1 3 show the control outline drawings and Figure 1 4 is the plant wiring diagram Engine stability and response are set by the controlling device not by the actuator and driver Follow the instructions for the controlling device while setting up the engine control system Pern Part Number Part Number Actuator Model CW to Max CCW to Max NG conrector son Pan 8405 012 Na 8405 015 Bani ting 8405 016 CW CCW to Max refers to the direction that the actuator rotates to increase fuel when looking at the rotor Table 1 1 ProAct Actuator Specifications 420 mA 0200 mA Cnirl Signal Cnirl Signal 420 mA 420 mA Driver 420 mA 0200 mA Actuator Actuator Model Cnirl Signal Cnirl Signal Pos Output Pos Output Model IIl 9905 386 9905 387 9905 459 9905 392 MS connector conduit fitting Mogel tv 9905 390 9905 391 9905 461 9905 460 MS connector conduit fitting Table 1 2 ProAct Driver Configurations Woodward 1 ProAct III IV Actuator Driver Manual 04127 Part Number J1 Ma
28. the adjustment procedure Woodward 17 ProAct III IV Actuator Driver Manual 04127 The actuator position feedback sensor is factory set and should not be adjusted r _ NA VE olerance Limits Limits for 4 20 mA Driver Tolerance OSITION CA ctuator 9 6 8 10 12 14 6 la 20 22 Current to Driver mA Figure 3 6 Tolerance Limits in Driver Setup 18 Woodward Manual 04127 ProAct III IV Actuator Driver Chapter 4 Troubleshooting Introduction Improper engine operation is often the result of factors other than governor operation This chapter gives tips about engine problems which can resemble governor problems Make sure the engine is operating correctly before making any changes in the governor Attempting to correct engine or load problems with untimely governor adjustment can make problems worse If possible isolate the governor from the engine to determine if the problem is with the governor and not with the engine or the load on the engine Governor faults are usually caused by problems in the installation or the linkage between the actuator and the engine Carefully review all the wiring connections the power supply and the linkage before making any adjustments to the actuator or driver Always check the fuel control linkage from stop to stop as if the actuator were moving it The linkage must move freel
29. the components or conductors on a printed circuit board with your hands or with conductive devices OBB IMPORTANT DEFINITIONS WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury CAUTION indicates a potentially hazardous situation which if not avoided could result in damage to equipment NOTE provides other helpful information that does not fall under the warning or caution categories 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 1994 All Rights Reserved Manual 04127 ProAct III IV Actuator Driver Contents ELECTROSTATIC DISCHARGE AWARENESS 1nmnnnmannnnnannnannnmnmnmnmnmmmnmnnnmznnzza II CHAPTER 1 GENERAL INFORMATION L keEeKR KEE ERR KEE KRR KEEN ERR KEEN ERR KENE 1 CHAPTER 2 DESCRIPTION OF OPERATION ccscssssseseccesseeecnseeseesneeeseeseeaeses 7 WAVE CO CUI GUO anc A eee Sec cae aaa a a APP 7 Electronic CircuitS nanna n Anna nnnnnn ana n ASAAN a aSa AEE 7 4 20 mA Output Models rna ann nr anna nanna am 8 Actuator Position Signal nn nn an nn an rr nr nanna rna t mn 8 AG i LEE 8 CHAPTER 3 INSTALLATION 0 20002002050 2080 nn nnnn mnn nnnenznnnnnnnnnn
30. ting Connector 5416 460 J2 Mating Connector 5416 461 Driver and Actuator J3 Mating Connector 203 889 ProAct III IV Connector Kit 8923 188 J1 J2 2 no JI J2 Mating Connector 90 1631 639 Driver and Actuator Table 1 3 ProAct Accessories 2 Woodward Manual 04127 ProAct III IV Actuator Driver 11 50 Si A J 7 p N Es DK A NN N i A Jj ka 17 5 2 LI 7 NS nl T WI WR a al Lagi Lal F 2 x 500 14 INCH NPTF BLACK Figure 1 1 ProAct Driver Outline Drawing Conduit version shown MS connector version has connector plugs Woodward 3 CTOR CONNE STYLE MS ProAct III IV Actuator Driver DI ON SHAFT PARENTH ES HES SH INC NOTE Manual 04127 Figure 1 2 ProAct Ill Actuator Outline Drawing Woodward ProAct III IV Actuator
31. y without friction and without backlash Some fuel controls will present problems at particular fuel or rack positions because of a hesitation or binding in the linkage Fuel supply and injector conditions can also present problems which resemble governor problems On spark ignited engines distributor coil points and timing problems can all cause improper operations which may resemble faulty governor control Linkage and Actuator Stroke Use as much of the 75 degrees of actuator stroke as possible Carefully follow the guidelines in the Driver Adjustments section of Chapter 3 in making linkage arrangements Using less than optimum actuator movement will make stability more difficult and will make the actuator more sensitive to external loading forces and friction Woodward 19 ProAct III IV Actuator Driver Manual 04127 Chapter 5 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 e Replacement Exchange 24 hour service e Flat Rate Repair e Flat Rate Remanufacture If you are experiencing problems with installation or unsatisfactory performance of an installed system the following options are available e Consult the troubleshooting guide in the manual e Contact Woodward technical assis
Download Pdf Manuals
Related Search