Woodward ProAct I Product Manual
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Woodward ProAct I Product Manual

Digital speed control system
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Product Manual 04121
(Revision M, 8/2015)
Original Instructions
ProAct™ Digital Speed Control System
for Models I and II
Installation and Operation Manual

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Summary of Contents for Woodward 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 Revisions—Changes in this publication since the last revision are indicated by a black line alongside the text. Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly undertaken.

  • Page 3: Table Of Contents

    Product Support Options ..................56   Product Service Options ..................56   Returning Equipment for Repair ................57   Replacement Parts ....................57   Engineering Services .................... 58   Contacting Woodward’s Support Organization ............ 58   Technical Assistance .................... 59 Woodward...
  • Page 4 Figure 1-2. ProAct Digital Speed Control and Actuator .......... 7   Figure 1-3. Example of ProAct II Actuator .............. 8   Figure 1-4. Outline Drawing of ProAct I or II Actuator ..........9   Figure 1-5. ProAct Wiring Diagram ............... 10  ...

  • Page 5: Warnings And Notices

    Start-up On- and off-highway Mobile Applications: Unless Woodward's control functions as the supervisory control, customer should install a system totally independent of the prime mover control system that...

  • Page 6: Electrostatic Discharge Awareness

    Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices. 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.

  • Page 7: Chapter 1. General Information

    (transient) and 2.7 N·m (2.0 lb-ft) of torque. The ProAct I is extremely fast and provides 3.4 J (2.5 ft-lb) of work (transient) and 1.4 N·m (1.0 lb-ft) of torque at steady state. ProAct I controls may be operated on nominal 12 Vdc systems.

  • Page 8: Control Applications

    The ProAct II control requires 18–32 Vdc (24 Vdc nominal) uninterrupted power supply, with 125 watts as the maximum power consumption at rated voltage. ProAct I requires 8–32 Vdc (12 or 24 Vdc nominal) uninterrupted power supply with 50 W as the maximum power consumption at rated voltage.

  • Page 9: Figure 1-1. Flexible Coupling

    Manual 04121 ProAct I/II Figure 1-1. Flexible Coupling Figure 1-2. ProAct Digital Speed Control and Actuator Woodward...

  • Page 10: Figure 1-3. Example Of Proact Ii Actuator

    ProAct I/II Manual 04121 Figure 1-3. Example of ProAct II Actuator Woodward...

  • Page 11: Figure 1-4. Outline Drawing Of Proact I Or Ii Actuator

    Manual 04121 ProAct I/II Figure 1-4. Outline Drawing of ProAct I or II Actuator Woodward...

  • Page 12: Figure 1-5. Proact Wiring Diagram

    ProAct I/II Manual 04121 Figure 1-5. ProAct Wiring Diagram Woodward...

  • Page 13: Figure 1-6. Outline Drawing Of Proact Control Box

    Manual 04121 ProAct I/II Figure 1-6. Outline Drawing of ProAct Control Box Woodward...

  • Page 14: Chapter 2. Description Of Operation

    The chassis should be bolted to a good ground to ensure effective EMI/RFI protection. An auxiliary ±2.5 volt input is provided to interface with Woodward Load Sensors, to provide isochronous load-sharing operation. Control Dynamics The algorithms used in the ProAct control are designed specifically for reciprocating engine applications.

  • Page 15: Figure 2-1. Window Width For Gain Ratio

    Manual 04121 ProAct I/II Alternate Dynamics The ProAct control provides two complete sets of dynamic adjustments, which are externally switch selectable. The two sets of dynamics are provided for use where engine operating conditions change, such as in systems which use two different fuels, clutched-in loads, and electrical power generation where the unit may be operated stand-alone and paralleled with an infinite bus.

  • Page 16: Fuel Limiters

    ProAct I/II Manual 04121 This feature eliminates the potentially damaging jiggle of the actuator and fuel system. The control automatically increases gain by an adjustable gain ratio when speed error exceeding an adjustable window occurs, or is anticipated to occur, based on measurements of the instantaneous rate of change of the entire engine.

  • Page 17: Figure 2-2. Start Fuel Limit

    Manual 04121 ProAct I/II Figure 2-2. Start Fuel Limit Transient Overfuel This feature allows the user to 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 good transient load acceptance while maintaining safe steady-state-horsepower limiting.

  • Page 18: Speed Reference And Ramps

    ProAct I/II Manual 04121 Torque Limit A two-slope torque limiter is provided for mechanical-drive, variable-speed applications. The torque limiter provides a maximum fuel position determined by current engine speed to limit over-fueling. The torque limiter is compared with the maximum fuel limit and the lower percent value is used as the actuator position limit.
  • Page 19 Manual 04121 ProAct I/II When Rated Speed is selected by closing the Idle/Rated switch contact, the fuel limit is set to the Maximum Fuel Limit set point value or the Torque Limit, whichever is less, for the current engine operating speed. The speed reference selected at this time is determined by the status of the Enable Remote switch.

  • Page 20: Droop/Isochronous

    ProAct I/II Manual 04121 Figure 2-5. Remote Speed Reference Droop/Isochronous The Droop/Isochronous switch allows selection of either type of governor operation. If Droop is selected, the ProAct control will hold engine speed according to a droop schedule entered in the program.

  • Page 21: Power Up Diagnostics

    Manual 04121 ProAct I/II Power Up Diagnostics The Power Up Diagnostics feature is provided to verify the proper operation of the microprocessor and memory components. The diagnostics take about ten seconds after the control is powered on. A failure of the test will turn off the output of the control.

  • Page 22: Return Spring

    ProAct I/II Manual 04121 Return Spring The ProAct actuator has an internal return spring designed to move the actuator toward minimum fuel in case the electrical control should fail, or power is removed. Spring scale may not be enough to move the engine to shutdown.

  • Page 23: Chapter 3. Installation

    Maximum power consumption is 125 W at rated voltage. The ProAct I system requires a voltage source of 8 to 32 Vdc (12 or 24 Vdc nominal). Maximum power consumption is 50 W at rated voltage.

  • Page 24: Actuator Installation Considerations

    Generally the heat transfer abilities of aluminum and low-carbon steel are better than high-carbon steel or stainless steel. Contact Woodward if operating temperature is a concern.

  • Page 25: Figure 3-1. Diesel Engine Travel Stops

    Manual 04121 ProAct I/II Figure 3-2. Carburetor Travel Stops Figure 3-1. Diesel Engine Travel Stops Actuator Bracket The actuator may be installed on a bracket holding to the 2.248–2.251 inch diameter male pilot concentric to the terminal shaft or to a bracket which attaches to the base with four .312-18 screws with a minimum engagement of 16 mm...

  • Page 26: Electrical Connections

    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 manual 50532, EMI Control for Electronic Governing Systems, for more information.

  • Page 27: Figure 3-5. Correct Wiring To Power Supply

    Manual 04121 ProAct I/II Figure 3-5. Correct Wiring to Power Supply Figure 3-6. Incorrect Power Supply Wiring Woodward...

  • Page 28: Actuator And Position Feedback Wiring

    ProAct I/II Manual 04121 Run the power leads directly from the power source to the control. DO NOT POWER OTHER DEVICES WITH LEADS COMMON TO THE CONTROL. Avoid long wire lengths. Connect the positive (line) to terminal 24 and the negative (common) to terminal 25.
  • Page 29 Manual 04121 ProAct I/II Idle/Rated Contact The Idle/Rated contact (open for Idle, closed for Rated) connects to terminal 17. When the Idle/Rated contact is closed, the control immediately switches the fuel limit to the maximum limit or torque limit (whichever is less) and ramps engine speed to the rated speed set point (or the speed specified by the Remote Input when the Remote Speed Setting input at terminal 21 is enabled).

  • Page 30: Speed Signal Input

    Aux Voltage Input Connect the output of a Woodward Load Sensor (if used) to terminals 12 (+) and 13 (–). Use a shielded twisted-pair cable. Wire the remainder of the load sensor in accordance with the wiring diagram for the sensor used.

  • Page 31: Control Outputs

    Manual 04121 ProAct I/II Control Outputs Actuator Control The actuator is connected to terminals 1 (+) and 2 (-). The polarity of this connection must be correct if the actuator is to respond in the desired rotational direction. The actuator cannot be reversed by changing the polarity because of the factory-installed return spring.

  • Page 32: Installation Checkout Procedure

    ProAct I/II Manual 04121 Installation Checkout Procedure With the installation complete as described in this chapter, do the following check out procedure before beginning the start-up adjustments in Chapter 4. Visual inspection Check the linkage or coupling between the actuator and fuel metering device for looseness or binding.

  • Page 33: Chapter 4. Operation And Adjustment

    Manual 04121 ProAct I/II Chapter 4. Operation and Adjustment Introduction Because of the variety of installations, plus system and component tolerances, the control must be tuned to each system for optimum performance. This chapter contains information on control calibration. It includes initial prestart-up and start-up settings and adjustments.
  • Page 34 NOT USED. black square Clears the error log from the programmer. Displays the software part number and revision. Use this information when contacting Woodward or an authorized service facility. NOT USED.  NOT USED. NOT USED.

  • Page 35: Figure 4-1. Hand Held Programmer (9907-205)

    Manual 04121 ProAct I/II The Programmer comes with a 54 inch long connecting cable and a “D” connector. Figure 4-1. Hand Held Programmer (9907-205) Woodward...

  • Page 36: Proact Control Menus

    ProAct I/II Manual 04121 ProAct Control Menus Menu 1—Dynamics Settings Menu Default High Item Value Value Value Units Gain A 0.0003 0.25 10.00 Gain A BP 0.00 100.00 Gain B 0.0003 0.25 10.00 Gain B BP 0.00 100.00 Gain C 0.0003...
  • Page 37 Manual 04121 ProAct I/II Menu 4—Limiter Settings Menu Default High Item Value Value Value Units Max Fuel Limit Transient Over Fuel Transient Time seconds Start Fuel Limit Start Ramp Rate %/second Start Speed 1200 Min Torque Limit Torque Limit BP...

  • Page 38: Description Of Menu Set Points

    None Self Test Result *—The correct result is 49. Contact Woodward if the result is not 49. Configuration, Menu 6, may be viewed at anytime. However, the engine must be shut down and the entry code must be increased from "0" to "49" before changes can be made to Menu 6.

  • Page 39: Figure 4-2. Typical Transient Response Curves

    Manual 04121 ProAct I/II Figure 4-2. Typical Transient Response Curves Woodward...

  • Page 40: Figure 4-3. Non-Linear Valve Power Curve

    ProAct I/II Manual 04121 Gas Engine Setup Change in the butterfly valve position is not linear in comparison to engine power output. In naturally-aspirated (non-turbocharged) engines, the position of the valve in comparison to engine output appears on a chart similar to Figure 4-3.

  • Page 41: Figure 4-5. Linearized Engine Plot

    Manual 04121 ProAct I/II Figure 4-5. Linearized Engine Plot Diesel Engine Setup Most Diesel engine fuel controls are nearly linear. The dynamics maps may still be used to accommodate nonlinear conditions caused either by the fuel system or by linkage between the actuator and the rack. For gain settings that are not used, set the associated Breakpoint at 100%.
  • Page 42 ProAct I/II Manual 04121 Step load the engine with as many load steps as are practical. At each load step, Gain A may need to be varied to maintain engine stability. Do not change stability or actuator compensation after the first setting in step b.

  • Page 43: Figure 4-6. Example Of Plot Created From Gain Column

    Manual 04121 ProAct I/II Set Gain A to the value recorded in Step 1b. This should give good control at no load. Use the plot of the engine to determine the linearity of the fuel system. This curve should be linearized between inflection points as shown in Figure 4-5.
  • Page 44 ProAct I/II Manual 04121 Stability, Actuator Compensation, Gain Ratio, Window Width 11. Stability (also known as Reset) compensates for the lag time of the engine. It adjusts the time required for the control to return the speed to zero error after a disturbance.
  • Page 45 Manual 04121 ProAct I/II Gain (for good Load Step control) Actuator Output Load Step 1 Load Step 2 Load Step 3 Load Step 4 Load Step 5 Load Step 6 Load Step 7 Load Step 8 Load Step 9 Load Step 10...

  • Page 46: Figure 4-8. Accel/Decel Example

    ProAct I/II Manual 04121 Decel Time is the time required for the control to ramp the engine speed from rated speed to idle speed. The time is set from 0 to 500 seconds. The ramp is started whenever the Idle/Rated switch is opened.

  • Page 47: Figure 4-9. Droop Curve

    Manual 04121 ProAct I/II 11. Droop is set as the percent rated speed will be decreased from no load to full load. Droop will be included in the engine control schedule only when the Isoch/Droop contact is open. The percentage of Droop entered is based on 75° of actuator travel. If less than full travel is used, the droop percentage must be increased proportionally.

  • Page 48: Figure 4-10. Idle Droop

    ProAct I/II Manual 04121 Figure 4-10. Idle Droop 19. Speed Switch C OFF sets the rpm that will turn off Speed Switch C. The speed switch changes state at the selected speed position. Each switch allows 500 mA to sink to the negative of the power supply when closed.
  • Page 49 Manual 04121 ProAct I/II Damage to the butterfly valve and possible jamming of the valve in the wide open position is possible if linkage is not designed to reach maximum actuator position at least 3° in advance of maximum butterfly valve position.

  • Page 50: Figure 4-12. Torque Limit Map

    ProAct I/II Manual 04121 Figure 4-12. Torque Limit Map Menu 5—Monitor Menu Input or output values displayed on the hand held are continuously updated. Descriptions of each menu item follow: Speed displays the current engine speed in rpm. Speed Reference displays the current speed reference in rpm. Note that this may not be the current speed of the engine due to the effect of idle droop, fuel limiters, auxiliary input, or droop.
  • Page 51 Manual 04121 ProAct I/II Idle/Rated Switch Status displays the status of discrete input at terminal 17. Closed indicates 24 Vdc is applied to the input selecting rated speed and the maximum fuel limit is selected. Open indicates idle speed and the idle fuel limit.

  • Page 52: Figure 4-13. Dynamics Map Curves

    ProAct I/II Manual 04121 The number of gear teeth is used by the control to convert pulses from the speed-sensing device to engine rpm. To prevent possible serious injury from an overspeeding engine, make sure the control is properly programmed to convert the gear-tooth count into engine rpm.

  • Page 53: Conclusion Of Test And Calibration Procedures

    Self Test Result displays the result of power up diagnostics performed on the microprocessor, data, and program memory. A successful test gives a result of 49. Contact Woodward if the self test result is not 49. Conclusion of Test and Calibration Procedures This completes the calibration instructions.

  • Page 54: Chapter 5. System Troubleshooting Charts

    ProAct I/II Manual 04121 Chapter 5. System Troubleshooting Charts Problem Cause Remedy Prime mover will not Supply voltage polarity Check for supply voltage from terminals 24 (+) to 25 start. Actuator not reversed, or no supply voltage. (–). Reverse leads if polarity is incorrect.
  • Page 55 Manual 04121 ProAct I/II Problem Cause Remedy Prime mover will not Speed sensor signal not Check wiring for proper connection. Check shields start. Actuator not clearing failed speed signal for proper installation. moving to start fuel circuit. position. (cont.) Speed sensor not spaced properly. Check for at least 1.0 Vac at terminals 10 and 11 during...
  • Page 56 ProAct I/II Manual 04121 Problem Cause Remedy Prime mover Control adjustment. Control may be adjusted for sluggish operation overspeeds only on causing overspeed on start. Slowly adjust GAIN for starts. fastest stable response. Stability may be adjusted too low. Increase Stability setting.
  • Page 57 Manual 04121 ProAct I/II Problem Cause Remedy Prime mover will not ProAct control. Adjust GAIN, Stability, and ACTUATOR stabilize at rated no- COMPENSATION in Menu 1 or 2. Check Gain load speed. The Breakpoint for the lower speeds. instability may occur...

  • Page 58: Chapter 6. Product Support And Service Options

    A current list of Woodward Business Partners is available at www.woodward.com/directory. Product Service Options Depending on the type of product, the following options for servicing Woodward products may be available through your local Full-Service Distributor or the OEM or Packager of the equipment system.

  • Page 59: Returning Equipment For Repair

    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.

  • Page 60: Engineering Services

    Field Service engineering on-site support is available, depending on the product and location, 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.

  • Page 61: Technical Assistance

    ProAct I/II Technical Assistance If you need to contact technical assistance, you will need to provide the following information. Please write it down here before contacting the Engine OEM, the Packager, a Woodward Business Partner, or the Woodward factory: General...

  • Page 62: Appendix . Menu Summary

    ProAct I/II Manual 04121 Appendix. Menu Summary Initial Prestart Settings These tables are provided for the convenience of the ProAct™ user. Each number should be recorded as it is programmed with the Hand Held Programmer. Any changes should be noted so the adjustment can be referenced from its original setting.

  • Page 63: Menu 3-Speed Reference Settings

    Manual 04121 ProAct I/II Menu 3—Speed Reference Settings Please refer to application note 51317, ProAct Digital Speed Control System with Start-up Fuel Limiting, if this is a fuel-limiting version. Default Actual Menu Item Setting Setting Rated Speed 1800 rpm ___________...

  • Page 64: Proact Control Menu Summary

    ProAct I/II Manual 04121 ProAct Control Menu Summary MENU 1—Dynamics Settings MENU 4—Limiter Settings Gain A Max Fuel Limit Gain A BP Transient Over Fuel Gain B Transient Time Gain B BP Start Fuel Limit Gain C Start Ramp Rate...

  • Page 65: Proact™ Control Specifications

    Manual 04121 ProAct I/II ProAct™ Control Specifications Operating Temperature –40 to +85 °C (–40 to +185 °F) Storage Temperature –55 to +100 °C (–67 to +212 °F) Vibration Sine Sweep, 6 hrs/axis, 24-2000 Hz 0.5 Oct./min input level 2.5 Gs Shock US MIL-STD-810C, Method 516.2, Procedure III...

  • Page 66: Revision History

    ProAct I/II Manual 04121 Revision History 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 update manual to latest formats and safety warnings.
  • Page 67 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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