89543-REV.

NEW

CPC
CURRENT TO PRESSURE CONVERTOR

STANDARD VERSION EXPLOSION PROOF VERSION

: 8901-455 : 9907-477

OPERATION, INSTALLATION AND CALIBRATION

WOODWARD GOVERNOR COMPANY

MANUAL 89543 REV.NEW

__________ WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing of 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 (overtemperature, or overpressure, where applicable) shutdown device, that operates totally independently of the prime mover control device(s) to protect against runaway or damage to the engine, turbine, or other type of prime mover with possible personal injury or loss of life should the mechanical-hydraulic governor or electric control, the actuator, fuel control, the driving mechanism, the linkage, or the controlled device fail. In the case of an explosion hazardous environment, ensure that there is not an explosion hazard present, prior to opening the flameproof (Eex-d) compartment. After the CPC has been powered down. Wait the time indicated on the nameplate, before removing the cover. 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.

CAUTION Electronic controls contain static-sensitive parts. Observe the following precautions to prevent damage to these parts.
N

Discharge body static before handling the control (with power to the control turned off, contact a grounded surface and maintain contact while handling the control) Avoid all plastic, vinyl and styrofoam (except antistatic versions) around printed circuit boards (PCBs or modules) Do not touch the components or conductors on a PCB with you hands or with conductive devices. When not installed in a control, modules should be kept in a protective antistatic bag.

Woodward Governor 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 stated.

Woodward Governor Company, 1996 All Rights reserved

Manual 89543-Rev.NEW

TABLE OF CONTENTS
CHAPTER 1 DESCRIPTION 1.1 INTRODUCTION ............................................................................................ 1-1 1.1.1 Hydraulic Schematic ................................................................................. 1-1 1.2 CONSTRUCTION ........................................................................................... 1-2 1.2.1 Housing...................................................................................................... 1-2 1.2.2 Hydraulic Valve......................................................................................... 1-2 1.2.3 Actuator ..................................................................................................... 1-2 1.2.4 Printed Circuit Board................................................................................. 1-2 1.2.5 Pressure Sensor.......................................................................................... 1-4 CHAPTER 2 SPECIFICATIONS 2.1 ELECTRIC ....................................................................................................... 2-1 2.2 HYDRAULIC................................................................................................... 2-1 2.3 PERFORMANCE............................................................................................. 2-2 2.4 ENVIRONMENTAL........................................................................................ 2-3 2.5 PHYSICAL....................................................................................................... 2-3 2.6 DEFAULT FACTORY SETTINGS ................................................................ 2-3 CHAPTER 3 INSTALLATION 3.1 RECEIVING INSTRUCTIONS ....................................................................... 3-1 3.2 UNPACKING INSTRUCTIONS ..................................................................... 3-1 3.3 MOUNTING INSTRUCTIONS....................................................................... 3-1 3.3.1 Location Considerations............................................................................ 3-1 3.3.2 Mounting the CPC (Figure 3-1)................................................................. 3-1 3.3.3 Hydraulic Connections .............................................................................. 3-2 3.3.4 I/H to CPC Special Mounting Adaptor ..................................................... 3-2 3.4 ELECTRICAL CONNECTIONS..................................................................... 3-3 CHAPTER 4 CALIBRATION 4.1 INTRODUCTION ............................................................................................ 4-1 4.2 CHECKOUT .................................................................................................... 4-1 4.2.1 Explanation of Adjustments and Test points............................................. 4-3 4.2.2 Set-up/Checkout procedure ....................................................................... 4-5 4.3 CALIBRATION ............................................................................................... 4-6 4.3.1 Output Pressure Vs. Command Input ........................................................ 4-6 4.3.2 Dynamic Adjustments ............................................................................... 4-6 4.3.3 Output Current Signal................................................................................ 4-7 4.3.4 Discrete Output Signal .............................................................................. 4-7 4.3.5 Dither......................................................................................................... 4-7 4.3.6 Finish Checkout......................................................................................... 4-8 CHAPTER 5 REPAIR INSTRUCTIONS 5.1 GENERAL........................................................................................................ 5-1 5.2 RETURN FOR REPAIR INSTRUCTION....................................................... 5-1 5.3 PROTECTIVE PACKAGING ......................................................................... 5-1 5.4 TROUBLESHOOTING ................................................................................... 5-2 5.4.1 General ...................................................................................................... 5-2 5.4.2 Troubleshooting Procedure ....................................................................... 5-2

Manual 89543-Rev.NEW APPENDIX A MANUFACTURERS DECLARATION OF CONFORMITY APPENDIX B OUTLINE DRAWING APPENDIX C WOODWARD ADAPTOR PLATE APPENDIX D EXTRACT OF KEMA CERTIFICATE APPENDIX E ADAPTOR PLATE I/H TO CPC

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Manual 89543-Rev.NEW

CHAPTER 1 DESCRIPTION
1.1 INTRODUCTION The Woodward CPC is a Current to Pressure Converter (CPC). It is intended for positioning steam and/or fuel valves and/or its associated servo systems. The CPC supplies a hydraulic fluid output pressure proportional to the 4-20 mA input current signal. Apart from accurate pressure control, the CPC is designed for easy mounting and servicing. The flat surface with three hydraulic connections mounts to a adaptor Figure 1-1 Front view of the CPC plate with the actual hydraulic fittings. This plate remains a part of the installation when removing the CPC, for example, during flushing of the lines when commissioning the installation. The customers cable enters the CPC via a cable gland. By unscrewing the cap, the easyto-access printed circuit board is revealed. The wires are connected to board-mounted terminals. Calibration and dynamic settings are completed by two sets of potentiometers on the board. 1.1.1 Hydraulic Schematic

Figure 1-2 Hydraulic Schematic

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Manual 89543-Rev.NEW

1.2 CONSTRUCTION The CPC consists of the following main parts: N Housing N Hydraulic valve N Actuator N Printed Circuit Board N Pressure Sensor These parts will be discussed further in the following sections.

1.2.1 Housing The housing is an aluminum, black anodized block, supporting all other parts. It contains the hydraulic ports and the mounting holes on one side of the square section and the cable gland on the other. Together with the cast aluminum, black anodized cover, the flameproof enclosure contains the electronics, the actuator and the pressure sensor. The spiral return spring is installed on the base and protected by a cover. The entire CPC construction is water and dust-proof, in accordance with class IP65. 1.2.2 Hydraulic Valve An innovative hydraulic valve controls the oil flow from supply to output port, or from output to tank. (see section 1.1.1). The valve consists of a steel bushing, in which a steel plunger moves. The special construction ensures proper, reliable and contaminanttolerant operation, using standard lube oil. Above the hydraulic section, the rotor and bushing, with integrated flame paths, ensure that the CPC complies with the CENELEC explosion-proof standards. 1.2.3 Actuator The actuator is a Woodward developed, rotary limited angle torque (LAT). It can be regarded as a stepping motor with steps of 90, operated using mini-stepping technique in one quadrant. The rotating angle is mechanically limited to H22.5. The rotor, with the permanent magnet, is directly coupled to the hydraulic valve. The current signal to the coils is generated by the driver circuit of the electronics. 1.2.4 Printed Circuit Board The printed circuit board is mounted on top of the housing. A functional block diagram is given in Figure 1-3. The printed circuit board performs the following tasks:

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Manual 89543-Rev.NEW

x x x x x x x x

Power supply Signal conditioning of input and output signals. PID output loop for output pressure PID output loop for valve position Actuator driver Current limiting Fault detection Dither generation

The power supply section performs the EMI filtering on the 18-32 Vdc input voltage and generates an internal +10 Vdc. The internal voltage is to power the circuit. The filtered input voltage is used to power the pressure sensor and the actuator driver.

Figure 1-3 Functional Block Diagram, detailing the electronics of the CPC

Each input and output signal from the print board is EMI protected. The 4-20 mA pressure signal from the internal pressure transmitter is transformed into a voltage signal. The Pressure Level and Pressure Range potentiometers tune this signal for the specified output pressure range. The 4-20 mA input signal gives a 1-5 Vdc signal, via a 250 : resistance. A relay provides a discrete contact for fault detection. A red lamp will light when the relay is active. The drive signal is monitored, and is detected when it exceeds its range for longer than two seconds. This indicates that the required level of output pressure is either too high or too low. When this occurs, the relay will change state. Set jumper to either JPR1 or JPR2. JPR1 gives a normally open alarm, and JPR2 gives a normally closed alarm. The Signal Range potentiometer adjusts the current output signal so that the minimum and maximum pressures correspond with 4 and 20 mA respectively.

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Manual 89543-Rev.NEW The actual valve position is measured by a non-contacting position sensor, integrated into the board. The pressure output loop, with adjustable gain and stability, generates a valve position reference signal for the valve position output loop, depending on the pressure reference signal and measured pressure signal. The dynamic settings can be adjusted to match the characteristics of the controlled servo system. The driver provides the actuator with a high current, pulse width modulated (PWM) signal, depending on the drive demand signal. The current passing through the actuator is monitored. It can go up to 5 A for a period of three seconds, boosting the torque of the actuator to its maximum. Then, the current is limited to approximately 1.5 A, in order to protect the circuitry. The drive demand signal checks that the CPC is functioning correctly. When the signal exceeds its normal operating window for longer than two seconds, the CPC is presumably unable to maintain the required pressure level and the relay will change state. A red lamp indicates when the alarm relay is active A dither signal can be superimposed on the drive signal. The amplitude and frequency can be adjusted. The dither signal is intended to give a relatively high frequency ripple on the output pressure. It can be used to reduce the effect of static friction in the CPC and the attached servo system.

1.2.5 Pressure Sensor The pressure sensor is a two wire 4-20 mA transmitter, also there is a third wire for shielding purposes. For the explosion-proof version, a special EEx-d transmitter is used.

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Manual 89543-Rev.NEW When the CPC is supplied with hydraulic and electric power, and a current input signal between 4 and 20 mA, it will output a certain pressure within the factory set pressure range. The operation is as follows. See also Figure 1-3 and Figure 1-4: 1. The pressure reference and actual pressure signals are compared by the pressure output loop, and generate a reference valve position signal. 2. The valve position is measured with a board-mounted sensor. The position signal, together with the valve position reference, is used by the position output loop with fixed dynamics. This provides a fast and stable valve position output. 3. The output loop outputs a drive signal. The driver generates the correct PWM high current signal to the actuator, which results in the valve position as required.

Figure 1-4 CPC shown in Cross Section

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Manual 89543-Rev.NEW 1. The hydraulic valve has two ports ; Supply to Output and Output to Tank. The three hydraulic connections are indicated on the CPC. 2. With the hydraulic valve in its mid position, both ports are closed, and, assuming no leakage is present, the output or output pressure is maintained at its level. 3. The output pressure is measured by the pressure transmitter. When either the output pressure or the pressure reference changes, it is detected by the electronics. As previously described, the valve position will change. 4. For an increase in output pressure, the change will result in an opening of the Supplyto-Output port, resulting in a flow from high pressure oil to the output port. For a decrease in pressure the Output-to-Tank port will be opened, allowing the oil to flow from the servo system to the tank. 5. With leakage of the servo system, the valve will always open the Supply to Output connection to a certain extent to maintain the output pressure. 6. A small difference in desired and actual valve position will cause position output loop to integrate to one of the extremes, thus assuring that the full actuator force is available for changing position. 7. Should this not result in the correct match of pressure reference and measured pressure, the electronics will detect the valve position requirement has been extreme. After two seconds the relay will change state, giving an external signal of a failing pressure output. 8. A return spring forces the valve to open the Output to Tank port, upon loss of power. This assures a fail-safe operation.

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Manual 89543-Rev.2

CHAPTER 2 SPECIFICATIONS
2.1 ELECTRIC Connections 9 terminals on the internal printed circuit board suitable for 0.5-4 mm2 solid or 0.5-2.5 mm2 stranded wire (22-12 AWG). Entry via cable gland. Cable dia. 9-12 mm. 18-32 Vdc (24 Vdc nominal) (use cable at least 1.5mm2/16 AWG) 8 W during steady state, 48 W maximum, 120 W peak.(Three seconds maximum) 4-20 mA into 250 :. CMRR Max. + 20 VDC 4-20 mA. Maximum external load: 300 :. Accuracy + 1% Relay. Jumper selectable for NO or NC. 100,000 operations. 1.0 A at 30 VDC, max. 33 VDC 0.75 A inductive at 28 VDC 0.2 Henry 10-30 Hz. Default setting is 30 Hz Zero is minimum and default. Maximum depends on adjusted frequency and dynamic characteristics of the entire system.

Cable Supply Voltage Power Consumption Current Input Signal Analog Output Signal Discrete Output Signal

Dither Frequency Dither Amplitude

2.2 HYDRAULIC Connections Flat mounting face with 3 holes, see Appendix B. Hydraulic connections via an adaptor plate (optional), see Appendix C for the Woodward adaptor plate. 17 bar (250 psi) maximum. At least 0.5 bar higher than the maximum output pressure At least 0.5 bar lower than the minimum output pressure. Min. level: 1 bar (14.5 psi), max. level: 15 bar (217.5 psi) Min. range: 1 bar (14.5 psi), max. range: 14 bar (203 psi) Filter 40 micron nominal, 75 micron absolute or better. (E40 = 75 or better). 20 to 100 cSt Depends on viscosity and supply pressure. See Figure 21. Depends on viscosity and pressure difference. See Figure 2-1. Reverse flow is 30-50 % greater than forward flow, due to a filter inside the CPC at supply input.

Supply Pressure Tank Pressure Output Pressure

Recommended Rating Viscosity Leakage Flow Capacity

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Manual 89543-Rev.NEW

Figure 2-1 Flow Characteristics

2.3 PERFORMANCE Frequency Response 10-30 msecs. time constant at small step, blocked load (No servo systems connected to the CPC).Time constant 30-300 msecs, with a total settle time of 100-500 msecs., if the hydraulic load has a time constant of up to two seconds. Ultimate dynamic response depends on total servo system and dynamic adjustments of the CPC. 0.2% of full range 0.1% of full range 0.1% of full range < 0.01% full range / C

Linearity Hysteresis Repeatability Temperature drift

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Manual 89543-Rev.2

2.4 ENVIRONMENTAL Ambient temperature Humidity Oil temperature Maximum surface temp. Vibration EMC -20 to +85C. 95 % relative humidity Continuously 60C max. Peak 80GC (2-3 days) 85C. Lloyds LR type approval test spec. 1 and 2 (5-100Hz at 4g). EN 50 081-2 and EN 50 082-2. Compliance with CE-mark immunity and emissions requirements for heavy industry environments. EN 50 014 and EN 50 018 (CENELEC flameproof) EEx d IIC T5. T6, KEMA 94.D.9629 X See extract of the certificate in Appendix D for details. IP65

Explosion safety

Water and dust proof

2.5 PHYSICAL See also the outline drawing 9989-410, in Appendix B. Height x Width x Depth Weight Mounting Approx. 220 x 170 x 170 mm (8.7 x 6.7 x 6.7 inch) Approx. 10 kg without oil Four M10 threaded holes, 20-24 mm deep, on the face with the hydraulic ports.

2.6 DEFAULT FACTORY SETTINGS Gain Stability Dither Amplitude Dither frequency Output pressure range = 30% = 30% = 0% = 30 Hz = 1.5 - 4.5 bar (1 turn potentiometer) (1 turn potentiometer) (1 turn potentiometer) (1 turn potentiometer) (4-20 mA)

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Manual 89543-Rev.2

CHAPTER 3 INSTALLATION
Unpacking and installation are covered in this chapter. 3.1 RECEIVING INSTRUCTIONS The CPC is carefully packed at the factory to protect it from damage during shipment. However, careless handling during shipment can result in damage. Notify the shipping company if damage is found.

3.2 UNPACKING INSTRUCTIONS Carefully unpack the CPC and remove it from the shipping container. Do not remove the shipping plate or plugs, until ready to mount.

3.3 MOUNTING INSTRUCTIONS 3.3.1 Location Considerations When selecting a location for the CPC, consider the following: N Provide adequate ventilation and avoid placing or attaching it to heat generating or conducting parts of the installation. N Locate the unit as close as possible to the servo: short hydraulic lines (and volume) help to achieve optimum response. N Avoid mounting at places with excessive vibration 3.3.2 Mounting the CPC (Figure 3-4) The CPC is designed for vertical or horizontal mounting. The CPC mounts to an adaptor block (or plate). The adaptor block connects the three hydraulic CPC ports with the external Oil-Supply, Turbine-Drain and Control-Output of the Steam Valve Servo. The CPC is attached (clamped) to the adaptor-block by M10 screws. The screws should stick at least 20mm or more inside the CPC for a reliable and solid mounting. Construction should allow easy removal and re-connection of the CPC by just loosening or fastening the M10 bolts. Allow space for removal of the cover, to gain access to the adjustments on the printed circuit board.

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Manual 89543-Rev.NEW Place the unit against the adaptor plate with the gasket in between and secure it with M10 screws and appropriate locking devices. Be sure that the hydraulic ports correspond with their designation. Optionally Woodward Governor can provide a mounting plate. This plate is made of steel, see Appendix C for the outline. These plates can be joined to the Turbine Frame, using two M12 screws or can be welded in place. 3.3.3 Hydraulic Connections Three hydraulic lines must be connected to the adaptor block (or plate): N S (supply): located left looking to the hydraulic connection plain of the CPC (figure 3-1) N O (Output): located at the centre N T (Tank): right S, O and T are marked on the CPC. The pipe inner diameters should be large enough to prevent excessive pressure loss during transient flow conditions. A minimum inner diameter of 12 mm is required. The CPC needs to be installed correctly (See chapter 3, Installation.) The pump capacity and/or associated accumulators needs to be large enough for the required slew rate of the attached servo system. Before installing the CPC, the hydraulic lines, supply, tank and the line from CPC to the controlled servo system, should be thoroughly flushed. 3.3.4 I/H to CPC Special Mounting Adaptor A special mounting pad is available to exchange the CPCs predecessor, the I/H convertor, with a CPC. See figure 3-1,3-2 and 3-3.

Figure 3-1 Obsolete European Design I/H Convertor

Figure 3-2 Obsolete U.S.A Design I/H Convertor

Figure 3-3 New CPC with I/H Adapter Block (existing hydraulic tubing left in place)

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Manual 89543-Rev.2

3.4 ELECTRICAL CONNECTIONS Apply local procedures, codes and directives for installing electrical/electronic equipment and, where applicable, for installation of explosion-proof devices in hazardous locations. The electrical power supply should be able to output 2A at 24 Vdc continuously, with a peak of 5 A during three seconds. The CPC has one cable entry, for cables sizes between 9 and 12 mm. The cable isolation must have a temperature rating of more than 80C continuous. 1. Strip the cable isolation (not the wire isolation) 12 cm down. Strip the wire isolation 5 mm down. Mark the wires according to their designation and install connectors, if required. 2. Remove the clamp screw and the rubber grommet of the cable gland and slide them over the wires in the correct order, until the grommet is at the end of the cable isolation. 3. Remove the CPC cover. Move the wires through the cable gland and up to the printed circuit board. 4. Re-install and tighten the clamp screw . The Teflon tube, provided with the CPC, can be used to protect the wires inside the CPC. 5. The wires are then connected to the terminals on the printed circuit board. The terminals accepts wires as specified in section 2.1. A wire size of 1 mm2 or AWG 18 is recommended for signals. 1.5 mm2 is recommended for power. The terminal designations are shown in table 1, chapter 4. Terminals 10 to 13 are pre wired at the Woodward factory and should not be changed. 6. Secure the cable outside the CPC to prevent pull forces on the cable gland.

Figure 3-4 Mounting of the CPC

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Manual 89543-Rev.NEW

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Manual 89543-Rev.2

CHAPTER 4 CALIBRATION

4.1 INTRODUCTION After installation of the CPC, it must be checked for proper operation and calibration before use. The functional test has been completed at the factory. Final checkout and customer calibration must be completed after installation. For default factory settings, please refer to section 2.6. ___________ WARNING Read this entire manual and all other publications pertaining to the work to be performed before installing, operating, or servicing of 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 (overtemperature, or overpressure, where applicable) shutdown device(s), that operates totally independently of the prime mover control device(s) to protect against runaway or damage to the engine, turbine, or other type of prime mover with possible personal injury or loss of life should the mechanicalhydraulic governor(s) or electric control(s), the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or the controlled device(s) fail. In the case of an explosion hazardous environment, ensure that there is not an explosion hazard present, prior to opening the flameproof (Eex-d) compartment. After the CPC has been powered down. Wait the time indicated on the nameplate, before removing the cover.

4.2 CHECKOUT A checkout of the CPC is done to verify proper installation, wiring and connection of the hydraulic lines.

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Manual 89543-Rev.NEW NOTE The checkout procedure will verify correct installation. This procedure is a bench test of the CPC. The checkout procedure cannot be run, if the prime mover is powered up.

Figure 4-1 PCB Component Location Table 1 Wiring List of Terminal Block 2 (for customer) Pin 1 and 2 + 24 VDC Power Supply Pin 3 Ground (Shield, if used) Pin 4 and 5 + 4-20 mA Input Signal Pin 6 and 7 + 4-20 mA Output Signal Pin 8 and 9 Relay Output Signal Terminal Block 1 (Factory connected) Pin 9 Actuator (Yellow) Pin 10 Actuator (Green) Pin 11 Pressure Sensor (White) Pin 12 Pressure Sensor (Grey) To shield via screw (Only Pressure Sensor Black standard version) Jumper setting JPR1 Connected NO JPR2 Connected NC (factory set)

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Manual 89543-Rev.2

4.2.1 Explanation of Adjustments and Test points Seven adjustments can be made and 14 test points have been provided. The adjustments are explained below. See Figure 4-1 for location of the potentiometers and test points (Tps). For default factory settings, please refer to section 2.6. Pressure Level This adjustment sets the level of output pressure. Adjusting the level changes all points of the output pressure uniformly. Adjusting clockwise increases the level. See Figure 4-2. This adjustment sets the slope of the output pressure. Adjusting clockwise increases the amount of slope of the line. See Figure 4-2.

Pressure Range

Figure 4-2 Output Pressure vs. Command Input

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Manual 89543-Rev.NEW Gain This adjustment sets the amount of gain (proportional action) for the pressure control circuit. In most cases, 50% gain can be used. High gain provides a fast response time, but can cause instability. This adjustment sets the stability (intergration-action) of the controller circuit. The stability cooperates with the Gain setting to provide a stable operation. Adjusting clockwise increases the stability. This adjustment sets the amplitude of the output dither. Dither is used to keep the hydraulic part of the CPC and attached servo systems from sticking, if necessary. The amplitude should be kept at a minimum to prevent objectionable oscillation. It is factory set to zero. Adjusting clockwise increases dither amplitude. This adjustment sets the frequency of the dither. It can be changed to accommodate different servo systems. It is factory set to maximum (|30 Hz). Adjusting counterclockwise decreases the frequency. This adjustment sets the range of the 4-20 mA output signal. The level is fixed. Using a jumper, the relay contact can be set to open normally (NO) or close normally (NC).

Stability

Dither Amplitude

Dither Frequency

Signal Range

Relay Jumper

The printed circuit board is provided with 14 test points (For use only by WGC Personnel). The voltages, measured at those test points, represent the following signals: TP1 TP2 TP3 TP4 TP5 TP6 TP7 TP8 TP9 TP10 TP11 TP12 TP13 TP14 Alarm Pressure (1.5 - 7.5 V) Error signal 5V= no error. Position Correct Position Drive Signal (Desired current through the core) 23V (18 - 23V) P - 4 - 20mA input signal 4mA=8.5V 20mA=2.5V Internal Power Supply (+ 10V) Ref. 5V GND internal CPC (not the same as +24V GND) Triangle Wave Signal PWM signal to driver Current through Coil, 6 V=+0.83 A, 5 V=0 A, 4 V=0.83 A

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4.2.2 Set-up/Checkout procedure 1. Verify that the correct hydraulical and electrical connections are complete, according to chapter 3. 2. Confirm that the hydraulic and electrical power to the CPC is turned off. 3. Remove the top cover of the CPC. (Wait for six minutes before removing cover, if using explosion proof version) 4. Connect a calibrated pressure gage to the control output line, in order to measure output pressure. 5. Connect a mA current source with a current meter, in series, to terminals 4 (+) and 5 (-). __________ WARNING To prevent personal injury or death and damage to equipment, the controlled device must not be allowed to run or operate during this procedure. The main steam valve or main fuel control must be turned off to prevent operation of the controlled device.

6. Apply electrical power to the CPC. The green LED will illuminate. 7. Check the power supply by measuring the voltage at terminal 1 and 2. 8. Check internal power supply at test pin TP 9 and TP 11. The reading should be +10V +0.1VDC 9. Start the hydraulic supply system and turn the current source on. Check that the oil is up to operating temperature and that all air has been purged from the system. The air can be purged by adjusting the current input signal up and down several times. Allow for warm-up time. 10. Observe the pressure gage when changing the current input signal. The pressure level should correspond with the default values specified in chapter 2.

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4.3 CALIBRATION

This section covers calibration and other electrical adjustments of the CPC. Refer to Figure 4-1 for location of the different potentiometers. 4.3.1 Output Pressure Vs. Command Input 1. Set the current source to 12 mA and measure the output pressure. 2. Adjust the Pressure Level for the desired output pressure. 3. Adjust the current source to 20 mA and measure the output pressure. 4. Adjust the Pressure Range for the desired output pressure. 5. Check 12 mA settings again, and adjust the level if necessary. 6. Check 4mA, and adjust output with range if necessary. Please note that turning range clockwise will result in a decrease of pressure. 7. Repeat steps 1 through 6 until the output pressures at both extremes fall in the desired tolerance. NOTE The pressure level and pressure range adjustments are 25 turn potentionmeters. 4.3.2 Dynamic Adjustments 1. Adjust the current source to 12 mA. 2. Adjust the Gain slowly clockwise to the middle position. If the controlled output pressure becomes unstable. Then adjust the Gain counterclockwise. Normally 50% gain can be used for all types of loads. 3. Turn it counter clockwise for small servo volumes, and clockwise for bigger servo volumes. Use 10%-20% stability for a small or blocked servo. Use 50%-60% for a bigger servo, with about two seconds time constant. Increase the stability further if the oil is cold or has a high viscosity. If high frequency oscillations are observed, the Stability can be decreased. Decreasing the Stability normally results in the possibility to further increase the Gain. 4. Check the stability over the full range by adjusting the input current between 4 and 20 mA in small stepwise changes.

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4.3.3 Output Current Signal This signal is factory calibrated. If needed, re-adjust as follows : 1. Connect a current meter to terminals 6 (+) and 7 (-). Set the input current source to 12 mA and measure the output current signal. 2. Adjust the Signal Range until the output signal is 12 mA. 3. Adjust the current source to 4 and 20mA and measure the output current signal. 4. Adjust the Signal Range until both the 4 and 20 mA fall within + 1% accuracy. The level is fixed to 0 mA. 4.3.4 Discrete Output Signal The jumper setting for a NO or NC contact is shown in Figure 4-1 When an error condition is present, such as incorrect pressure or incorrect position at the internal valve, the relay will switch and the red lamp will illuminate. This major alarm has a set and reset time of two seconds. A non resetable function of the relay can be achieved by adding an external relay circuit.

4.3.5 Dither The dither can be adjusted while the prime mover is operating. Beware of unacceptable oscillations when introducing dither. It is recommended to always use some dither. 1. Turn the Dither Amplitude clockwise to increase the amplitude until oscillation of the output pressure or valve position can be observed. Decrease the amplitude slightly to prevent objectionable wear in the system. 2. If the frequency is too high for the attached servo system, reduce it by turning the Dither Frequency counterclockwise. Due to the dynamic characteristics of the CPC, the amplitude of the pressure fluctuations will normally increase when reducing the frequency.

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4.3.6 Finish Checkout 1. Turn off the milli amp source. 2. Remove the milli amp current source and (re)connect the plant wiring. 3. Remove additional current and/or voltmeters and (re)connect the plant wiring. 4. If applicable, remove the pressure gage from the control output hydraulic line. 5. Re-install the cover. For explosion-proof units: re-install the locking block. The CPC is now ready for normal operation.

__________ WARNING To protect against personal injury, loss of life, and/or property damage when starting the engine, turbine, or other type of prime mover, be prepared to make an emergency shutdown to protect against runaway or overspeed should the mechanical-hydraulic governor, or electric control; the driving mechanism, the linkage, or the controlled device fail.

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CHAPTER 5 REPAIR INSTRUCTIONS

5.1 GENERAL The CPC can only be repaired in the field, by skilled Woodward service personnel. Repairs and servicing of the unit must be performed by Woodward Governor Company or its authorized service facilities. For explosion-proof units, replacement of the cable gland by an uncertified (not EExd) cable gland or with another thread size, is not allowed. Removal or vandalism of the nameplate is prohibited.

5.2 RETURN FOR REPAIR INSTRUCTION Should the CPC need to be returned for repair, attach a tag on the unit. Include the following information on the tag: 1. 2. 3. 4. 5. Customer's name and address. The name and location at which the equipment is installed. Complete Woodward part number and serial number. Description of the failure. Instructions as to what type of repair is to be done.

5.3 PROTECTIVE PACKAGING The following procedures are used for protective packaging of the CPC, if returning for repair: 1. Install shipping plates or plugs in all hydraulic connection ports or seal with tape. 2. Wrap the unit with packaging materials that will not damage the surface of the unit. 3. Place in a double walled packing carton. 4. Place at least 10 centimeters of tightly packed industry approved shock absorbing material around the unit. 5. Secure the carton with strong tape around the outside of the carton to increase the strength of the carton.

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5.4 TROUBLESHOOTING 5.4.1 General The following troubleshooting guide will help you isolate trouble with the control circuit board, actuator, wiring or elsewhere. Troubleshooting beyond this level is recommended ONLY when a complete facility for control testing is available. The wrong voltage can damage the control. When replacing a control, check the power source and wiring connections for the correct voltage.

5.4.2 Troubleshooting Procedure Table is a general guide for isolating system problems. Before using the guide, make sure that the system wiring contacts, and input/output connections are correct and in good working order. Complete the checks in order. Each check assumes that the preceding checks have been completed and any problems have been corrected.

__________ WARNING To protect against personal injury, loss of life, and/or property damage when starting the engine, turbine, or other type of prime mover, be prepared to make an emergency shutdown to protect against runaway or overspeed should the mechanical-hydraulic governor, or electric control; the driving mechanism, the linkage, or the controlled device fail.

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PROBLEM No pressure out. CAUSE Faulty power, check green lamp. Error condition, check red lamp. (= alarm = discrete output is active). Power supply too weak. Power supply is limiting current. REMEDY Check power connections. 24VDC at pin 1 and 2. (Pin 1 should be plus). If on: Check actuator wire connection. If off: Check pressure sensor wires. Change power supply. See specification. Change limit level to maximum. (>= 5A).

Full pressure out.

Bad power supply. Use WG recommended power supply. Pressure sensor wrong connected. Check wire connection, table1 chapter 4. Other faulty wire harness. Check wire connection, table1 chapter 4.

Slow dynamics.

Filter not clean. Clean filter. See figure 5.1 Dynamic adjustments not optimal. Raise stability and maybe gain. Cold oil (too high viscosity).

Wait till normal temp is reached or change dynamic adjustments (raise stability). Too small or too long tubes. Use bigger or/and shorter tubes. Water in oil. Clean or change the oil. Oscillation, high frequence. Servo is outside its working range. Nothing, this is normal. Oil viscosity changed. Faulty valve position feedback. Oscillation, low frequence. High friction in servo. Abnormal high friction in servo. Low CPC internal friction. High CPC internal friction. Is the red lamp on? Re adjust dynamics or dither too high. Contact WGC service Change dither amplitude and frequence. Clean or change servo piston. Change dither amplitude and frequence. Contact WGC service. If yes: Check the jumper. It must be set! No: Check pressure range. See specifications Adjust the output. See calibration. Replace faulty wire(s). Replace faulty wire(s). Check pressure sensor and actuator. Reinstall all wires. Lower temperature. See specification Fasten the pressure sensor.Check oring. Contact WGC service. Clean or change servo piston. Contact WGC service. Replace the return spring. Reduce tank pressure.

Alarm not working.

4-20 mA output not working. Occasional disturbance.

Not correct calibrated. Wires broken. Wire protection broken. Wire protection broken, internal CPC Bad contact at connectors. Too high ambient or oil temperature. Pressure sensor is loose.

Leakage inside CPC.

Other reasons. Abnormal high friction in servo. Abnormal high internal friction. Not zero pressure at power Return spring is broken. off. Tank pressure is too high. Big pressure hysteresis.

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Figure 5-1 Removing filter from CPC

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APPENDIX A MANUFACTURERS DECLARATION OF CONFORMITY

PRODUCT IDENTIFICATION Product: Application: Manufacturer: Type: CPC Current to Pressure Converter for prime mover control Woodward Governor Nederland BV Part numbers 8901-455 and 9907-477

MEANS OF CONFORMITY The product is in conformity with Directive 89/336/EEC based on test results using harmonized standards in accordance with Article 10.1 of the Directive. TESTING Carried out at :

Dare!! Electronics, Woerden, The Netherlands NMi Certin B.V., Delft, The Netherlands Woodward Governor Company, Loveland, USA EN 50081-1:1991 EN 50082-2:1994 XN 165-R1 XN165-R25 XN 165-R29

Standards used : Test Reports :

MANUFACTURER Company : Woodward Governor Nederland B.V. Hoofdweg 601 2131 BA Hoofddorp The Netherlands Representative : Mr. T. Lloyd, Plant Manager Date : January 1997

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APPENDIX B OUTLINE DRAWING

>mm@

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APPENDIX C WOODWARD ADAPTOR PLATE

>mm@

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APPENDIX D EXTRACT OF KEMA CERTIFICATE

NOTE This is an extract of the original certificate and shall be used for reference only. For a complete copy, please refer to your supplier. (1) (2) (3) CERTIFICATE OF CONFORMITY KEMA No. Ex-94.D.9629 X This certificate is issued for the electrical apparatus: Pressure Converter type CPC (4) Manufacturer: Woodward Governor Nederland BV Hoofdweg 601 2131 BA Hoofddorp The Netherlands This electrical apparatus and any acceptable variation thereto is specified in the Annex to the certificate and the documents therein referred to. KEMA, being an Approved Certification Body in accordance with Article 14 of the Council Directive of the European Communities of 18 December 1975 (76/117/EEC), confirms that the apparatus has been found to comply with the harmonized European standards: EN 50 014 - 1977 + A1-A5, General requirements EN 50 018 - 1977 + A1-A3, Flameproof enclosure d and has successfully met the examination and test requirements, which are recorded in a confidential test report. The apparatus marking shall include the code: EEx d IIC T6 ... T5 Arnhem, 19 March 1996 Description The CPC is an electrical current to hydraulic pressure converter, used for positioning valve actuators. The relation between temperature class, maximum ambient temperature and maximum hydraulic oil temperature is shown in the table below.

(5)

(6)

(7)

(8) (9)

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APPENDIX E ADAPTOR PLATE I/H TO CPC

NOTE Woodward product I/H has been made obsolete. It can easily be replaced by the CPC using the adaptor plate 3689-097.

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Woodward Governor Company Turbomachinery Controls Hoofdweg 601 2131 BA Hoofddorp The Netherlands Tel: +31(0)23 5661111 Fax: +31(0)23 5636529