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04121M

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

1000 East Drake Road, Fort Collins CO 80525, USA

Phone +1 (970) 482-5811

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Fax +1 (970) 498-3058

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Summary of Contents for ProAct I

Page 1: ...Product Manual 04121 Revision M 8 2015 Original Instructions ProAct Digital Speed Control System for Models I and II Installation and Operation Manual...

Page 2: ...amage 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...

Page 3: ...21 Actuator Installation Considerations 22 Fuel Position Stops 22 Electrical Connections 24 Power Supply 24 Actuator and Position Feedback Wiring 26 Discrete Inputs 26 Speed Signal Input 28 Remote Sp...

Page 4: ...el 15 Figure 2 4 Torque Limit 16 Figure 2 5 Remote Speed Reference 18 Figure 2 6 Droop Speed Setting 18 Figure 2 7 ProAct Output Travel 19 Figure 3 1 Diesel Engine Travel Stops 23 Figure 3 2 Carbureto...

Page 5: ...control system An overtemperature or overpressure shutdown device may also be needed for safety as appropriate Personal Protective Equipment The products described in this publication may present risk...

Page 6: ...improper handling read and observe the precautions in Woodward manual 82715 Guide for Handling and Protection of Electronic Controls Printed Circuit Boards and Modules Follow these precautions when wo...

Page 7: ...tems ProAct II controls require nominal 24 Vdc supply Larger output ProAct III and ProAct IV controls are available Information on these actuators is in manual 04127 The ProAct Digital Speed Control i...

Page 8: ...oAct control It plugs into the serial port J1 connector of the control Generator Load Sensor part number 9907 026 for load sharing or droop parallel generator applications This will connect to the Aux...

Page 9: ...Manual 04121 ProAct I II Woodward 7 Figure 1 1 Flexible Coupling Figure 1 2 ProAct Digital Speed Control and Actuator...

Page 10: ...ProAct I II Manual 04121 8 Woodward Figure 1 3 Example of ProAct II Actuator...

Page 11: ...Manual 04121 ProAct I II Woodward 9 Figure 1 4 Outline Drawing of ProAct I or II Actuator...

Page 12: ...ProAct I II Manual 04121 10 Woodward Figure 1 5 ProAct Wiring Diagram...

Page 13: ...Manual 04121 ProAct I II Woodward 11 Figure 1 6 Outline Drawing of ProAct Control Box...

Page 14: ...minimizes the effects of engine torsionals or irregularities in the gear used for sensing speed This provides exceptionally smooth steady state control and allows the control dynamics to be matched to...

Page 15: ...engines which operate with different fuels or have load type changes which require different dynamics Gain Ratio is the ratio of Gain setting during transient off speed conditions to the gain setting...

Page 16: ...ll usually require all four gain settings for different fuel flows especially if the actuator is direct coupled to the butterfly Most diesel applications will need only one or two of the gain settings...

Page 17: ...set the Maximum Fuel Limit near the rated engine horsepower The Transient Overfuel will allow exceeding this Maximum Fuel Limit for a tunable percentage for a tunable time Transient Time This ensures...

Page 18: ...this section carefully to be sure your switch gear sequencing provides the proper operating modes The control provides an Idle Rated discrete input with tunable Idle and Rated Speed settings Raise and...

Page 19: ...or during the idle to rated ramp the speed reference will ramp to the speed reference value determined by the milliamps on the remote speed setting input based on the Raise Rate Lower Rate set points...

Page 20: ...2 6 Droop Speed Setting The droop schedule is based on a full 75 degrees of actuator rotation between minimum and maximum fuel If less than 75 degrees of rotation is used the amount of droop is reduce...

Page 21: ...ide 2 7 N m 2 0 lb ft of torque 3 4 J 2 5 ft lb work with 6 A 24 V input at steady state and 5 4 N m 4 0 lb ft of torque 6 8 J 5 0 ft lb work with 12 A 24 V input during transient The actuator is equi...

Page 22: ...or control but should not limit the actuator s ability to properly control the engine under all operating conditions The Feedback Device The feedback device is located on the closed shaft of the actua...

Page 23: ...input voltage range If a battery is used for operating power an alternator or other battery charging device is necessary to maintain a stable supply voltage To prevent damage to the control make sure...

Page 24: ...pling is used it should be drilled and pinned or serrated The bracket that mounts the actuator must be of adequate precision to assure that misalignment limits of the coupling used are not exceeded Co...

Page 25: ...be mounted in any attitude The actuator is weather proof and resistant to the corrosive effects of water and salt water however pressure washing of the feedback device side of the actuator should be m...

Page 26: ...e 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...

Page 27: ...Manual 04121 ProAct I II Woodward 25 Figure 3 5 Correct Wiring to Power Supply Figure 3 6 Incorrect Power Supply Wiring...

Page 28: ...w the electrical connection instructions The control common is electrically isolated from the power supply input Actuator and Position Feedback Wiring The ProAct actuator will rotate in either directi...

Page 29: ...nal 19 When the Raise Speed contact is closed the control raises speed at a rate determined by the Raise Rate set point When the contact is open speed remains at its current value Closing the Raise Sp...

Page 30: ...om all other conducting surfaces We recommend that the MPU be dedicated to the control The MPU output should be from 1 to 60 Vrms The Number of Gear Teeth is the number of teeth which will be exposed...

Page 31: ...onnects the device attached to the switch to ground The total length of the wire between the speed switches and the signal lamp or relay should not exceed 8 m 26 ft The switches are configured in Menu...

Page 32: ...is used If a resistance less than infinite is obtained remove the connections from each terminal one at a time until the resistance is infinite Check the line that was removed last to locate the fault...

Page 33: ...the control Firmly seat the connector on the terminal into J1 Control boxes are equipped with a cover which must be removed to access the J1 receptacle and the two other terminal strips When power is...

Page 34: ...eases the displayed set point rapidly 1 2 3 4 5 6 0 Accesses Menus 1 2 3 4 5 6 or 0 Number keys are NOT used to change displayed values 7 8 9 NOT USED Removes an inactive menu from the display screen...

Page 35: ...Manual 04121 ProAct I II Woodward 33 The Programmer comes with a 54 inch long connecting cable and a D connector Figure 4 1 Hand Held Programmer 9907 205...

Page 36: ...0 0003 0 10 10 00 NA Alt Gain C BP 0 00 60 100 00 Alt Gain D 0 0003 0 10 10 00 NA Alt Gain D BP 0 00 100 100 00 Alt Stability 0 00 1 0 10 00 seconds Alt Compensation 0 00 0 20 10 00 seconds Alt Gain R...

Page 37: ...itch A On Off Speed Switch B On Off Speed Switch C On Off Fault Lamp On Off Menu 6 Configuration Set Points Menu Low Default High Item Value Value Value Units Configuration Key 0 0 100 NA Number of Ge...

Page 38: ...s are settings that affect the stability and transient performance of the engine A large number will provide a faster response to an error between actual speed and reference speed A small number will...

Page 39: ...Manual 04121 ProAct I II Woodward 37 Figure 4 2 Typical Transient Response Curves...

Page 40: ...3 Non linear Valve Power Curve Turbocharged engines distort this curve particularly as turbo pressure builds to the point of operating the waste gate A turbocharged gas engine will likely have a butt...

Page 41: ...ally occurs in gas engine applications A plot of the fuel system must be determined to properly adjust the gain of the control to match the gain of the system at all loads The plot reflects the actuat...

Page 42: ...llecting the data for the Gain Plot Gain settings reflect the amount of slope as shown in Figure 4 4 Flat portions of the engine plot will require relatively small amounts of gain steep portions of th...

Page 43: ...tuator output versus load plot 6 Gain B should now be adjusted to obtain good control at the inflection point Note you may already have obtained the correct value in Step 1c 7 Set the Gain C Breakpoin...

Page 44: ...y state actuator movement 14 Window Width is the magnitude in rpm of a speed error at which the control automatically switches to fast response The control does not use the absolute value of speed err...

Page 45: ...the engine in rpm 2 Idle Speed Reference sets the speed in rpm at which the engine is operated at start up It sometimes is used during cool down 3 Raise Limit is the maximum speed reference setting i...

Page 46: ...n the Remote Speed Setting input is changed in the increase direction The rate programmed is in rpm per minute A step change in the remote input does not cause an immediate change in the reference whi...

Page 47: ...ttings may be required to achieve the desired results 13 Idle Droop Breakpoint is normally set equal to the actuator output obtained when the engine is unloaded and at low idle When the output of the...

Page 48: ...h Settings Menu 4 Limiter Settings Fuel limiters limit the actuator output from the control Descriptions of each menu item follow 1 Maximum Fuel Limit sets the maximum percent actuator output when rat...

Page 49: ...uel Limit or the Torque Limit whichever is less 6 Start Speed sets the speed in rpm that will remove the start fuel limit from the control system When Start Speed is obtained the speed ramps to idle o...

Page 50: ...he current percent of Actuator output This is useful for setup of the control fuel limiters torque limiter idle droop and gain breakpoint settings 4 Aux Input displays the voltage on the Aux Input 5 R...

Page 51: ...switch 16 Speed Switch A terminal 3 indicates the on off position of the switch 17 Speed Switch B terminal 4 indicates the on off position of the switch 18 Speed Switch C terminal 5 indicates the on o...

Page 52: ...e speed for each map 4 Failsafe Function Use Rabbit or Turtle keys Up to enable Down to disable The Failsafe function causes the ProAct control to issue a minimum fuel signal should the MPU signal fai...

Page 53: ...uctions Save the set points by pressing the SAVE key on the Hand Held Programmer Power down the control for about 10 seconds Restore power and verify that all set points are as recorded To prevent pos...

Page 54: ...ator for opens or shorts Check the polarity of the actuator and feedback Check actuator and linkage for proper installation and operation Problems may be direction of rotation linkage worn components...

Page 55: ...engine revolution against the number entered in step 2 of Menu 6 If no voltage is present magnetic pickup may be open circuited or shorted Make resistance check with the leads disconnected from contro...

Page 56: ...time Prime mover Check for proper operation of prime mover fuel system If actuator moves toward minimum fuel during overspeed problem may not be connected with the governor Speed not regulated huntin...

Page 57: ...a separate battery placed next to the prime mover After starting the prime mover if necessary apply load to check stability If stability occurs when the control is mounted next to the prime mover retu...

Page 58: ...e 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 b...

Page 59: ...is applicable to mechanical products only Returning Equipment for Repair If a control or any part of an electronic control is to be returned for repair please contact your Full Service Distributor in...

Page 60: ...on these services please contact one of the Full Service Distributors listed at www woodward com directory Contacting Woodward s Support Organization For the name of your nearest Woodward Full Service...

Page 61: ...uel gas gaseous diesel dual fuel etc Power Output Rating Application power generation marine etc Control Governor Information Control Governor 1 Woodward Part Number Rev Letter Control Description or...

Page 62: ...ain C 0 25 0 025 0 050 ___________ Gain C break point 60 100 100 ___________ Gain D 0 25 0 025 0 050 ___________ Gain D break point 100 100 100 ___________ Stability 0 25 sec 1 0 sec 1 0 sec _________...

Page 63: ...___________ Speed Switch B On 1200 rpm ___________ Speed Switch B Off 1140 rpm ___________ Speed Switch C On 2000 rpm ___________ Speed Switch C Off 1900 rpm ___________ Menu 4 Limiter Settings Pleas...

Page 64: ...op Idle Droop BP Speed Switch A On Speed Switch A Off Speed Switch B On Speed Switch B Off Speed Switch C On Speed Switch C Off MENU 4 Limiter Settings Max Fuel Limit Transient Over Fuel Transient Tim...

Page 65: ...810C Method 516 2 Procedure III Transit Shock US MIL STD 810C Method 516 2 Procedure IV EMI RFI Conducted Susceptibility Frequency Hz Amplitude Vrms Power Leads 30 1000 3 0 1000 10 000 3 5 10 000 8 00...

Page 66: ...tory Changes in Revision M Changed Feedback Device information Other corrections as indicated by Change bars Changes in Revision L Revision advanced to coordinate with new installation sheet and to up...

Page 67: ...9 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 a...

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