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Woodward CPC-DX, Original Instructions Manual

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Woodward CPC-DX Original Instructions Manual Download Page 58

Manual 26824 

CPC-II Unit Replacement Procedure 

 

 

 

48 

Woodward 

Chapter 3. 

Product Service Options 

If you are experiencing problems with the installation, or unsatisfactory 
performance of a Woodward product, the following options are available: 

Consult the troubleshooting guide in the manual. 

Contact the manufacturer or packager of your system. 

Contact the Woodward Full Service Distributor serving your area. 

Contact Woodward technical assistance (see “How to Contact Woodward” later 
in this chapter) and discuss your problem. In many cases, your problem can be 
resolved over the phone. If not, you can select which course of action to pursue 
based on the available services listed in this chapter. 

 

OEM and Packager Support:

 Many Woodward controls and control devices are 

installed into the equipment system and programmed by an Original Equipment 
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the 
programming is password-protected by the OEM or packager, and they are the 
best source for product service and support. Warranty service for Woodward 
products shipped with an equipment system should also be handled through the 
OEM or Packager. Please review your equipment system documentation for 
details. 

 

Woodward Business Partner Support: 

Woodward works with and supports a 

global network of independent business partners whose mission is to serve the 
users of Woodward controls, as described here: 

A 

Full Service Distributor

 has the primary responsibility for sales, service, 

system integration solutions, technical desk support, and aftermarket marketing 
of standard Woodward products within a specific geographic area and market 
segment. 

An 

Authorized Independent Service Facility (AISF)

 provides authorized 

service that includes repairs, repair parts, and warranty service on Woodward's 
behalf. Service (not new unit sales) is an AISF's primary mission. 

A 

Recognized Engine Retrofitter (RER)

 is an independent company that does 

retrofits and upgrades on reciprocating gas engines and dual-fuel conversions, 
and can provide the full line of Woodward systems and components for the 
retrofits and overhauls, emission compliance upgrades, long term service 
contracts, emergency repairs, etc. 

A 

Recognized Turbine Retrofitter (RTR)

 is an independent company that does 

both steam and gas turbine control retrofits and upgrades globally, and can 
provide the full line of Woodward systems and components for the retrofits and 
overhauls, long term service contracts, emergency repairs, etc. 

 

You can locate your nearest Woodward distributor, AISF, RER, or RTR on our 

website at: 

www.woodward.com/directory

 

 

 

Summary of Contents for CPC-DX

Page 1: ... Individual CPC II Converter Replacement Procedure 26824 Revision NEW Original Instructions CPC DX Current to Pressure Converter Dual Transfer Skid Individual CPC II Converter Replacement Procedure ...

Page 2: ...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 Translated Publications If the cover of this publication states Translation of the Original Instructions please note...

Page 3: ...s 2 Introduction 3 CHAPTER 2 ONLINE CPC II UNIT REPLACEMENT 8 System preparation to unit replacement 10 CPC II Unit disassembly from the CPC DX Skid 16 Electrical wires disassembly from removed CPC unit failed 24 New CPC II Unit hardware Installation procedure 29 New CPC II unit software settings loading procedure 36 CHAPTER 3 PRODUCT SERVICE OPTIONS 48 Replacement Parts 49 Engineering Services 49...

Page 4: ...ng plate 13 Figure 2 10 Supply Isolation valves CLOSED and locked out with padlock 14 Figure 2 11 CPC DX Installation Drawing Drain ports location 15 Figure 3 1 CPC II voltage measurement and verification 18 Figure 3 2 TWIN Terminals system handling 18 Figure 3 3 Replaced CPC II wires disconnected inside Electrical Terminal box 19 Figure 3 4 Unscrew a conduit nut from Electrical Terminal Box fitti...

Page 5: ...e 5 6 CPC II wires installation 35 Figure 6 1 CPC II with installed RS 232 connection cable 36 Figure 6 2 CPC DX health link orange switches in run position and secured with switching locks white piece 36 Figure 6 3 CPC DX with applied electrical power green LED illuminate 37 Figure 6 4 Loading the Settings File to the CPC II device 37 Figure 6 5 Basic parameters verification 38 Figure 6 6 Basic p...

Page 6: ...in a live on line replacement could result in turbine overspeed loss of control plant shutdown property damage and severe bodily injury including death Proper converter configuration and dynamic settings are unique to specific end applications It is the responsibility of the end user to determine the specific configuration and dynamic settings necessary for each specific converter application This...

Page 7: ... hand Equipment that should be considered includes but is not limited to Eye Protection Hearing Protection Hard Hat Gloves Safety Boots Respirator Always read the proper Material Safety Data Sheet MSDS for any working fluid s and comply with recommended safety equipment Start up Be prepared to make an emergency shutdown when starting the engine turbine or other type of prime mover to protect again...

Page 8: ...o 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 It is recommended when performing the removal of a CPC II converter from the CPC DX skid that the isolation valves be secured with appropriate locks and tags in accordance with the installation sites safety procedures ...

Page 9: ...ectricity on your body by not wearing clothing made of synthetic materials Wear cotton or cotton blend materials as much as possible because these do not store static electric charges as much as synthetics 2 Do not remove the printed circuit board PCB from the control cabinet unless absolutely necessary If you must remove the PCB from the control cabinet follow these precautions Do not touch any p...

Page 10: ...equirements is the responsibility of the manufacturer of the machinery into which this product is incorporated 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 2 applications Risque d explosion Ne pas raccorder ni débrancher tant que l installation est s...

Page 11: ...stem CCW Counter Clockwise CW Clockwise List of Woodward Reference Literature Manual 26455 Customer Publication Cross Reference and Revision Status Distribution Restrictions Product Manual 26615 CPC II Current to Pressure Converter with Enhanced Dynamics Reference Manual 26455 Woodward Energy Segment Customer Publications Cross Reference by Application Revision Status Distribution Restrictions Pro...

Page 12: ...nd Size 1 3 8 in Type Hex Head Size 8 mm Torque Screwdriver s Installation required torques ranges screwdriver end type and size 5 3 7 0 lbf in 0 6 0 8 Nm Type Slotted Tip Size 0 6 x 3 5 mm 35 39 lbf in 3 9 4 4 Nm Type Slotted Tip Size 6 5 X 1 2 mm 22 0 26 5 lbf in 30 36 Nm Type Phillips Tip Size PH 3 Screwdriver s Type Slotted Tip Size 3 5 X 0 6 mm Type Slotted Tip Size 6 5 X 1 2 mm Type Type Phi...

Page 13: ...contacts also can be connected to system indication lights lamps plant DCS to assist with system health monitoring The CPC DX uses a specially designed fast switching hydraulic valve to ensure minimal control switchover time and minimal system control pressure disturbance This special valve allows the pressure converter with the highest pressure output to control the process while blocking the out...

Page 14: ...Manual 26824 CPC II Unit Replacement Procedure 4 Woodward Figure 1 2 CPC DX Installation Drawing Front view Figure 1 3 CPC DX Installation Drawing Top view ...

Page 15: ...Manual 26824 CPC II Unit Replacement Procedure Woodward 5 Figure 1 4 CPC DX Installation Drawing customer interface view ...

Page 16: ...ment Procedure 6 Woodward Figure 1 5 CPC s wiring diagram WIRES TO J BOX WIRES TO J BOX 4 5 6 7 8 9 10 18 20 11 12 13 15 14 16 2 3 31 30 29 28 27 26 25 17 15 24 23 22 20 21 19 33 32 34 1 CPC II Unit 2 TERMINALS CPC II Unit 1 TERMINALS ...

Page 17: ...8 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 4 5 6 7 8 9 10 11 12 13 14 21 22 23 24 25 26 27 28 29 30 31 32 33 34 1 2 3 SIGNALS FROM CPC II UNIT 1 SIGNALS FROM CPC II UNIT 2 CUSTOMER SIGNALS TO CPC II UNIT 2 CUSTOMER SIGNALS TO CPC II UNIT 1 15 20 16 17 18 19 T E R M I N A L Figure 1 6 Electrical Terminal Box wiring diagram ...

Page 18: ...e procedures suitable for specific end applications and ensure that personnel are fully trained on such procedures prior to attempting to replace a converter on a live running turbine All safety protective systems overspeed over temperature overpressure etc must be in proper operational condition prior to the start of an on line replacement procedure Personnel should be equipped with appropriate p...

Page 19: ... unit To create a new settings file from CPC II Using PC Service Tool go to the Settings tab from pull down menu select Save from Device to File and save to an appropriate folder on your computer See Woodward manual 26615 for more details Figure 2 1 Saving CPC II Settings File creating back up It is good practice to make a back up file which can be used to restore the original settings should a pr...

Page 20: ...center gage marked on hydraulic manifold with CONTROL The CPC II currently controlling process will have a matching pressure indicated on its gage markings on hydraulic manifold CPC II Unit 1 pressure gauge marked with CPC 1 CPC II Unit 2 pressure gauge marked with CPC 2 The unit Not In Control or Failed should indicate a lower or zero 0 pressure Figure 2 2 Unit In Control verification using CPC D...

Page 21: ...ing control W I R ES FR O M C PC s 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 15 20 20 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 4 5 6 7 8 9 10 11 12 13 14 21 22 23 24 25 26 27 28 29 30 31 32 33 34 1 2 3 SIGNALS FROM CPC II Unit 1 SI G N AL S F RO M C PC I I Un i t 2 CUSTOMER SIGNALS TO CPC II Unit 2 CUSTOMER SIGNALS TO CPC II Unit 1 15 20 16 17 18 19 MA ST ER S LA VE R E L AY C P C I I U n i...

Page 22: ...27 28 29 30 31 32 33 34 4 5 6 7 8 9 10 11 12 13 14 21 22 23 24 25 26 27 28 29 30 31 32 33 34 1 2 3 SIGNALS FROM CPC II Unit 1 S I G NA L S FR O M C P C I I Un it 2 CUSTOMER SIGNALS TO CPC II Unit 2 CUSTOMER SIGNALS TO CPC II Unit 1 15 20 16 17 18 19 C U S TO ME R E L E C TR I C A L P O W E R S U P P L Y P r o t e c t i v e D e v i c e CPC II Unit 1 P r o t e c t i v e D e v i c e _ CPC II Unit 2 C...

Page 23: ...OSED lever position Figure 2 8 Control Isolation valve CLOSED and locked out with padlock lock not provided with the CPC DX unit Additionally valve position OPEN CLOSED could be verified by markings on valve locking plate see figure 2 9 Figure 2 9 Open Close markings on isolation locking plate ...

Page 24: ...pply pressure is present on the CPC unit otherwise the control output pressure can increase suddenly and cannot be controlled by the input setpoint This could cause the turbine to overspeed The supply pressure isolation valve and the control pressure isolation valve should always be closed prior to closing the drain line During replacement procedure close and lock out the drain port in case of pos...

Page 25: ...Manual 26824 CPC II Unit Replacement Procedure Woodward 15 Figure 2 11 CPC DX Installation Drawing Drain ports location ...

Page 26: ...ed When you disconnect CPCs health link the operating CPC will indicate Redundancy Fault alarm A Open the CPC DX Electrical Terminal Box unscrewing 4 four screws using screwdriver Type Phillips Tip Size PH 3 CCW direction B Verify if all wire ends and terminals are properly marked if not complete it according to Figure 1 6 Electrical Terminal Box wiring diagram Redundancy Fault ...

Page 27: ...position installing the wedges The voltage values listed below indicate which unit is in control Confirm that these readings are consistent with the indication of the gages Measure voltage between terminal Number Voltage V When CPC 1 is shut down unit to be replaced Shutdown CPC II Unit 1 Running CPC II Unit 2 15 and 16 7 20 and 19 3 When CPC 2 is shut down unit to be replaced Running CPC II Unit ...

Page 28: ...erter which to be removed TWIN Terminals system terminals 15 and 20 Upper screw is used to hold foreground wire lower screw is used to hold background wire see Figure 3 2 below Figure 3 2 TWIN Terminals system handling See electric diagram shown on Figure 1 5 and figure 1 6 During this operation be careful and do not disconnect running CPC II connections ...

Page 29: ...conduit use open end style wrench size 1 1 2 in Figure 3 4 Unscrew a conduit nut from Electrical Terminal Box fitting CCW direction Example how to attach lifting strap to lift CPC II unit see figures 3 5 6 7 Heavy object approximately 49 lbs 22 kg To avoid injury use lifting aids and proper lifting techniques when removing and replacing Do not lift or handle the CPC II by any conduit ...

Page 30: ...PC II Unit Replacement Procedure 20 Woodward Figure 3 5 Lifting strap installation Figure 3 6 Lifting strap properly installed Figure 3 7 Lifting strap properly installed CPC II unit on the CPC DX hydraulic manifold ...

Page 31: ... the bottom of the CPC DX hydraulic manifold Hex socket size 8 mm Typical wrench shape is shown on picture below Screw size metric SOC HD Cap M10 x 1 50 3 15 inch 80 mm long 4 pieces Figure 3 8 Long socket wrench Figure 3 9 CPC II mounting bolts view bottom of the hydraulic manifold Watch for hydraulic leakage at the manifold CPC interface during this operation ...

Page 32: ...e bottom Some minor oil spilling is normal a significant continuous leak is not normal If significant leakage occurs retighten the CPC II mounting bolts stop and wait until system can be taken off line Figure 3 11 Oil spillage from removed CPC II unit Be prepared to use a clean lint free oil absorbent cloth to clean up the spilled oil ...

Page 33: ...ard 23 Figure 3 12 Fitting with installed plastic plug Figure 3 13 CPC DX manifold with secured hydraulic passages after CPC II unit removal shown yellow plastic plugs not provided with the CPC II unit Figure 3 14 CPC II unit removed from CPC DX assembly ...

Page 34: ...amp CCW direction Unscrewing the cover hold CPC II unit in a vice with smooth protective brass or plastic protectors to prevent damage to the converter main housing To unscrew CPC II cover CCW direction place a 1 m bar between the two cover lugs Figure 4 2 Loosening CPC II cover with bar Verify if all wire ends and terminals are properly marked if not complete it according to Figure 1 5 CPCs wirin...

Page 35: ...C II terminal blocks view CPC II cover removed A Unscrew 4 four screws using slotted screwdriver Tip Size 3 5 X 0 6 mm Figure 4 4 CPC II terminal blocks 4 four mounting screws localization CPC II cover removed Figure 4 5 Unscrewing 2 two CPC II terminal blocks CCW direction ...

Page 36: ... Replacement Procedure 26 Woodward B Remove wire block gently pull out using screwdriver Figure 4 6 CPC II wire blocks pulling out A Carefully cutout cable ties using Cable Tie Removal Tool Figure 4 7 CPC II cable ties cutout ...

Page 37: ... size PH3 CCW direction Figure 4 8 CPC II Ground wire unscrewing C Remove wires from terminal blocks Use screwdriver Type Slotted Tip Size 3 5 X 0 6 mm CCW direction Figure 4 9 CPC II wires removal from terminal block D Unscrew a nut wrench type Open End Size 1 5 in CCW direction Figure 4 10 CPC II conduit nut unscrewing ...

Page 38: ...Manual 26824 CPC II Unit Replacement Procedure 28 Woodward E Gently pull out cable from CPC II housing Do not pull out the wiring from the conduit Figure 4 11 CPC II cable and conduit removal ...

Page 39: ...paragraph 3 1 to 3 2 Use previously disassembled wires with conduit from replaced CPC II unit A Use electrical tape and cable tie to pull cable through CPC conduit entry B Isolation tape and cable tie C Wires tape wrapping D Cable tie fixing with isolation type to conduit E CPC cable ready to install F CPC cable installation ...

Page 40: ... could be necessary H Install wires on terminal blocks See Figure 1 5 CPCs wiring diagram Use screwdriver Type Slotted Tip Size 3 5 X 0 6 mm Torque wires clamp screw in terminals to 5 3 7 lbf in 0 5 0 6 Nm CW direction I Install two 2 terminal blocks Use screwdriver Type Slotted Tip Size 3 5 X 0 6 mm Torque 4 four screws to 5 3 7 lbf in 0 5 0 6 Nm CW direction ...

Page 41: ...Manual 26824 CPC II Unit Replacement Procedure Woodward 31 J Install GND wire Use screwdriver Type Phillips Tip Size PH 3 Torque to 3 7 lbf ft 5 1 Nm CW direction K Secure wires with wire ties ...

Page 42: ...essurized oil which could present a risk of burn or fire hazard Incorrect operation or improper tuning could cause erratic operation when the system is operated automatically by the turbine control system Proper tuning is essential before transferring to automatic operation Make sure that supply and control isolation valves are closed during installation of the CPC II unit Open and close all valve...

Page 43: ...e 5 2 CPC II wires inside Electrical Terminal Box Use a long hex wrench 2 5 2 7 inch 63 69 mm to tighten 4 four bolts CW direction Access to the bolt from the bottom of the CPC DX manifold Hex socket size 8 mm Typical wrench shape is shown on picture below Figure 5 3 Long socket wrench Screw size metric SOC HD Cap M10 x 1 50 3 15 inch long 80 mm 4 pieces torque to 20 25 lbf ft 27 34 Nm ...

Page 44: ...olts tightening CW direction as viewed from the bottom Tighten the conduit nuts to 100 128 lbf ft 136 174 Nm Use open end style wrench size 1 1 2 in CW direction Figure 5 6 CPC II conduit nut tightening CW direction Double check the wiring connections before applying power Make sure that all wires are connected to the proper terminals and tightened correctly ...

Page 45: ...es before complete mechanical and electrical unit installation process Install all wires inside Electrical Terminal Box according to Figure 1 5 CPC s wiring diagram and Figure 1 6 Electrical Terminal Box wiring diagram Use torque screwdriver to install wires in terminals Type Slotted Tip Size 0 6 x 3 5 mm Torque to 5 3 7 0 lbf in 0 6 0 8 Nm CW direction Figure 5 6 CPC II wires installation ...

Page 46: ...2 or Zone 2 applications Make sure the area is non hazardous Connect CPC II and PC Serial port using RS 232 cable male connectors Launch and connect the service tool For newer PCs or laptops with USB ports rather than serial ports a USB to serial converter is required An approved converter can be obtained from Woodward P N 8928 1151 Figure 6 1 CPC II with installed RS 232 connection cable Figure 6...

Page 47: ...stablished with Service Tool download the appropriate settings file previously created into new CPC II unit please refer to User Manual 26615 A back up file can be uploaded into CPC II unit from the following a Archived back up settings file b Copied from the failed unit depending on failure type Figure 6 4 Loading the Settings File to the CPC II device Verify if basic settings match desired syste...

Page 48: ...ng parameters verification Dynamic Settings Parameters Make sure that Dynamic Performance Parameters match comparing Unit Not In Control to Unit In control Only the Load Leakage Parameters could cud have different value is specific for each unit only the Load Leakage Parameters could not match ...

Page 49: ...utdown condition is annunciated by red LED indicator Point 3 Setpoint is equal or below 4 mA Point 4 Setpoint Fault condition is annunciated be red LED indicator Figure 6 6 Basic parameters verification Operate the CPC II unit in Manual Mode by setting the setpoint to the minimum control pressure See PC Service Tool tab Performance Trend and Manual Operation Parameter Manual Control Settings o Mod...

Page 50: ...Manual 26824 CPC II Unit Replacement Procedure 40 Woodward Figure 6 7 Manual Control Mode Enabled ...

Page 51: ...he supply line when drain line is closed on the CPC unit otherwise the control output pressure can increase suddenly and cannot be controlled by the input setpoint This could cause the turbine to overspeed The drain isolation valve should always be open prior to opening the supply line Unlock isolation valve removing padlock and turn to open position Figure 6 8 Isolation valve OPEN CLOSED lever po...

Page 52: ...essary adjust Primary Gain of the replaced unit at the midpoint of the control range for rapid control response with minimal overshoot Some overshoot is permissible as it is necessary for displacement of the servo See Performance Trend and Manual Operation screen PC Service Tool Step 3 Primary Gain Figure 6 10 Primary Gain adjustment ...

Page 53: ...nimal ringing and stable control See Performance Trend and Manual Mode screen PC Service Tool Figure 6 11 Performance verification on Performance Trend chart B Check performance by switching between the midpoint and the low point of the control range Typically the performance will be more stable at this operating point if tuned properly for high pressure and mid pressure performance Figure 6 12 Pe...

Page 54: ...PC Service Tool Manual Control Settings o Mode Disabled Figure 6 13 Manual Control Mode Disabled Verify if the replaced CPC II unit has pressure offset at the same level as the unit in control default is 0 8 bar See PC Service Tool tab Redundancy Overview Parameter In Slave Mode Setpoint is Decreased by ...

Page 55: ...Manual 26824 CPC II Unit Replacement Procedure Woodward 45 Figure 6 14 Pressure offset value verification between CPC II units ...

Page 56: ...e Pressure feedback is stable and match pressure setpoint signal If possible or when appropriate to bring the turbine or process to a safe level verify the switching performance between CPC s Close PC Service Tool connection clicking Disconnect see Figure 6 16 and disconnect RS 232 interface cable from CPC II communication port Figure 6 15 PC Service Tool communication disconnection with CPC II Fi...

Page 57: ...l cover by rotating CW and hand tighten only to snug by placing a 1 meter bar between the two cover lugs Figure 6 17 CPC II cover tightening Install and torque the locking clamp screw to 35 39 lbf in 3 9 4 4 Nm in CW direction Use flat torque screwdriver Type Slotted Tip Size 6 5 X 1 2 mm Figure 6 18 CPC II locking clamp tightening ...

Page 58: ...cumentation for details Woodward Business Partner Support Woodward works with and supports a global network of independent business partners whose mission is to serve the users of Woodward controls as described here A Full Service Distributor has the primary responsibility for sales service system integration solutions technical desk support and aftermarket marketing of standard Woodward products ...

Page 59: ...ur worldwide locations or from one of our Full Service Distributors The field engineers are experienced both on Woodward products as well as on much of the non Woodward equipment with which our products interface For information on these services please contact us via telephone email us or use our website www woodward com Contacting Woodward s Support Organization For the name of your nearest Wood...

Page 60: ...er Type of Fuel gas steam etc Power Output Rating Application power generation marine etc Control Governor Information Control Governor 1 Woodward Part Number Rev Letter Control Description or Governor Type Serial Number Control Governor 2 Woodward Part Number Rev Letter Control Description or Governor Type Serial Number Control Governor 3 Woodward Part Number Rev Letter Control Description or Gov...

Page 61: ...Manual 26824 CPC II Unit Replacement Procedure Woodward 51 Revision History Changes in Revision NEW Initial release ...

Page 62: ...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 ...

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