Table of Contents
Advertisement
Quick Links
Advertisement
Table of Contents
Troubleshooting
Subscribe to Our Youtube Channel
Related Manuals for Woodward CPC-DX
Summary of Contents for Woodward CPC-DX
- Page 1 Released Product Manual 26758 (Revision B, 3/2017) Original Instructions CPC-DX Current to Pressure Converter Dual Transfer Skid (For hydraulic pressure systems) CPC-DX SKID 10 BAR PN: 8918-116 CPC-DX SKID 25 BAR PN: 8918-118 Installation and Operation Manual...
- Page 2 Revisions— A bold, black line alongside the text identifies changes in this publication since the last revision. 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
Released Manual 26758 CPC-DX Current to Pressure Converter Contents ....................... 3 ARNINGS AND OTICES ..................4 LECTROSTATIC ISCHARGE WARENESS ......................5 EGULATORY OMPLIANCE 1. G ....................7 HAPTER ENERAL NFORMATION Introduction ..............................7 System Description ............................7 Design Characteristics ..........................9 ... - Page 4 Figure 4-2. CPC-DX Unit with All Isolation Valves in CLOSED Position ............ 28 Figure 4-3. CPC-DX Unit CPC-II Unit #1 with Supply and Control Isolation Valves in Open Position ..29 Figure 4-4. CPC-DX Unit With All Isolation Valves in OPEN Position ............30 ...
-
Page 5: Warnings And Notices
Released Manual 26758 CPC-DX Current to Pressure Converter Warnings and Notices Important Definitions This is the safety alert symbol used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death. -
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: Regulatory Compliance
Field wiring must be suitable for at least 85 °C and 10 °C above the maximum fluid and ambient temperatures. The CPC-DX must be used in an ambient temperature range from –40 to +85°C (-40 to + 185⁰F). The working fluid temperature must be in range +15 to +70°C (+59 to 158⁰F). - Page 8 Released Manual 26758 CPC-DX Current to Pressure Converter Explosion Hazard—Do not connect or disconnect while the circuit is live unless the area is known to be non-hazardous. Substitution of components may impair suitability for Class I, Division 1 or 2 or Zone 2 applications.
-
Page 9: Chapter 1. General Information
Mechanical-Hydraulic Controls System Description The Woodward CPC-DX Dual Transfer Skid is a dual redundant, Current-to-Pressure Converter system. Its typical application is to control steam valves by interfacing redundant turbine controllers or signals to a single steam control valve servo mechanism. -
Page 10: Figure 1-1. Basic Cpc-Dx Application And Configuration
For the online CPC-II replacement procedure, see Woodward manual 26824 The CPC-DX Dual Transfer Skid supplies a precise and stable hydraulic control pressure proportional to the (4 to 20) mA input current signal. The system described in this manual consists of a skid-mounted arrangement of two CPC-II’s operating through a transfer valve assembly as shown in Figure 1-1. -
Page 11: Design Characteristics
Not In Control unit is continuous demonstration of its availability to assume control when needed. The CPC-DX uses a specially designed fast-switching high signal select valve to ensure minimal control switchover time and minimal system control pressure disturbance. -
Page 12: Figure 1-3. Cpc-Dx Installation Drawing Front View
DCS to assist with system health monitoring. The CPC-DX ports are represented as SUPPLY for the supply oil port, DRAIN CPC 1 and DRAIN CPC 2 for the drain (tank) lines, and CONTROL for the CPC-DX control oil connection to the control system as shown in Figure 1-5. -
Page 13: Figure 1-4. Cpc-Dx Installation Drawing, Top View
Released Manual 26758 CPC-DX Current to Pressure Converter Figure 1-4. CPC-DX Installation Drawing, Top view Woodward... -
Page 14: Figure 1-5. Cpc-Dx Customer Interface
Released Manual 26758 CPC-DX Current to Pressure Converter Figure 1-5. CPC-DX customer interface Woodward... -
Page 15: Figure 1-6. Cpc-Dx Main Terminal Box, Wiring Diagram
Released Manual 26758 CPC-DX Current to Pressure Converter The wiring for the CPC-DX skid is shown in Figures 1-6 and 1-7. The required minimum wiring for proper operation is as follows: Supply Power (18 to 32) V (dc), 24 V (dc) nominal for each converter ... -
Page 16: Figure 1-7. Cpc-Dx Main Terminal Block Connections List
Released Manual 26758 CPC-DX Current to Pressure Converter Figure 1-7. CPC-DX Main Terminal Block Connections List Woodward... -
Page 17: Figure 1-8. Internal Cpc Wiring Diagram
Released Manual 26758 CPC-DX Current to Pressure Converter Figure 1-8. Internal CPC wiring diagram Woodward... -
Page 18: Chapter 2. System Specifications
HYDRAULIC DRAIN CPC-II Unit #1 connection 1.312-12 UN straight thread port HYDRAULIC DRAIN CPC-II Unit #2 Note: For more details, see Figure 1-5. Note: Hydraulic ports per Woodward Inc. SS-145 (MS 16142 except minor diameter to accept “J” threads) Woodward... - Page 19 The maximum control pressure setting must be less than 70% of the supply pressure for optimum dynamic performance. The default offset value of 0.8 bar is sufficient to ensure CPC-DX operation with flow to the control line up to 23 l/min (6 US gpm) at oil viscosity up to to 55 cSt.
-
Page 20: Figure 2-1. Internal Leakage, Cpc-Dx Skid, 10 Bar Supply Pressure, Oil Viscosity 20 Cst
Released Manual 26758 CPC-DX Current to Pressure Converter Figure 2-1. Internal Leakage, CPC-DX Skid, 10 bar supply pressure, oil viscosity 20 cSt; Figure 2-2. Internal Leakage, CPC-DX Skid, 25 bar supply pressure, oil viscosity 20 cSt; Woodward... -
Page 21: Chapter 3. Installation
Field wiring must be suitable for at least 85 °C and 10 °C above the maximum fluid and ambient temperatures. The CPC-DX must be used in an ambient temperature range from –40 to +85°C (-40 to + 185⁰F). The working fluid temperature must be in range +15 to +70°C (+59 to 158⁰F). -
Page 22: Mounting Instructions
Temperature ratings are included in the specification section of this manual. The CPC-DX Dual Transfer Skid assembly is carefully packaged at the factory to protect it from damage during shipping. However, careless handling may result in damage to the unit. If any damage to the CPC-DX is discovered, notify both the shipping agent and Woodward. -
Page 23: Hydraulic Connections
CPC-DX Current to Pressure Converter Hydraulic Connections There are four hydraulic ports on the backside of the CPC-DX manifold. These are clearly marked SUPPLY for the supply oil port, DRAIN CPC 1 and DRAIN CPC 2 for the drain (tank) line, and Hydraulic CONTROL (HC) for the control oil connection to the servo system. -
Page 24: Figure 3-2. Power Supply Input Connections
CPC-II UNIT #1 90 W (2 s) 24 V (dc) nominal (18 to 32) V (dc), CPC-II UNIT #2 90 W (2 s) 24 V (dc) nominal Figure 3-2. Power Supply Input Connections For additional electric requirements, see Woodward manual 26615. Woodward... -
Page 25: Figure 3-3. Wiring Connections For Master Designation
Discrete Output 3 of the other unit. This wiring is provided from the factory, but must remain in place for the switching performance to operate as designed. During CPC-DX unit configuration be sure that: BOTH units aren’t configured as a “MASTER”... -
Page 26: Figure 3-4. Pe Ground Connection Localization And Details
- Any Alarm or Shutdown Indication - Operation as Master - In Control The Default Discrete Output settings for CPC-DX SKID are: Discrete Output 1: Configured as Any Alarm and Shutdown Status. Discrete Output 2: Configured as In Control/Not in Control Status. -
Page 27: Shielded Wiring
RS-232. Wiring The junction box CPC-DX has two 3/4 inch NPT and two 1/2 inch NPT wiring entries (see Figure 1-5). The cable insulation must have a temperature rating of at least T + 10 °C above the maximum ambient... -
Page 28: Chapter 4. Operation
Manual 26758 CPC-DX Current to Pressure Converter Chapter 4. Operation Perform the following procedure steps in the order as stated while commissioning and tuning the CPC-DX skid: Only trained personnel should be allowed to work on this device during operation. -
Page 29: Figure 4-1. Isolation Valve Open / Closed Lever Position
Shut down and tag out the turbine or controlled process in accordance with site operating procedures. Attach the CPC-DX skid to a solid mounting location using six (6) M14x2 Class 8.8 minimum screws (not delivered with unit) and washers (delivered with unit) in accordance with Figure 1-5. Typical tightening torque 67 ±... -
Page 30: Figure 4-2. Cpc-Dx Unit With All Isolation Valves In Closed Position
CPC-II installation or CPC-DX skid maintenance. Make sure that CPC-DX skid drain port is opened before supply valve opening. Make sure that turbine or operated process is in a shutdown condition when activating CPC-II converter Manual Mode. -
Page 31: Figure 4-3. Cpc-Dx Unit Cpc-Ii Unit #1 With Supply And Control Isolation Valves In Open Position
Slowly open the Drain isolation valve on one side of the CPC-DX skid ( CPC-II unit #1). Slowly open the Supply isolation valve on one side of the CPC-DX skid (first CPC-II unit #1). Slowly open the Control isolation valve on one side of the CPC-DX skid (first CPC-II unit #1). -
Page 32: Figure 4-4. Cpc-Dx Unit With All Isolation Valves In Open Position
Close the Control pressure isolation valve to the first CPC. Figure 4-5. CPC-DX Skid with CPC-II Unit #1 Control Isolation Valve in CLOSED Position Use the PC Service Tool to confirm the 2nd CPC dynamic parameters for optimal dynamic response. -
Page 33: Figure 4-6. Cpc-Dx Status Link Disconnection Inside Main Terminal Box
Discrete input #1. To confirm which unit is actually in control of the CPC-DX skid output pressure the unit in control status should be verified by the status of discrete output 2, the status indication in the service tool, and the pressure indicated on the gages. -
Page 34: Cpc-Dx Performance
Master/Slave switchover. CPC-DX performance The CPC-DX skid characterize very short transfer time and stable control pressure during unit to unit control switchover and in case of unit in control fault or shutdown. Special shuttle valve design provide “pressure bumpless” switchover between CPCs which minimize disturbance on servo valve or other control system. -
Page 35: Figure 4-8. Cpc-Dx Unit Control Takeover (Second Unit Shutdown Simulation)
26615 settings. CPC-DX Unit Tuning To properly tune up CPC-DX unit, please follow the instructions below in the specific sequence as described. 1. Determine the appropriate pressure offset between CPC-II Unit #1 and CPC-II Unit #2. The software within the CPC-II allows the user to adjust the pressure offset between CPC-II Unit #1 and CPC-II Unit #2. -
Page 36: Figure 4-9. Cpc-Dx Skid Pressure Between Cpc-Ii Units (Pressure Offset) At 20 Cst Oil Viscosity
[GPM] CONTROL LINE FLOW Figure 4-9. CPC-DX Skid Pressure between CPC-II Units (Pressure Offset) at 20 cSt Oil Viscosity The offset can be adjusted via the PC service tool by adjusting the value displayed as “In Slave Mode Setpoint is Decreased to:” See manual 26615, Section - Configure Redundancy. -
Page 37: Figure 4-10. Tuning Runs Showing The Effect Of Adjusted Primary Gain Example Parameter Values
Released Manual 26758 CPC-DX Current to Pressure Converter Tuning runs showing the effect of example parameter values are shown below. Dynamic Tuning Example Dynamic Tuning Example Primary Gain 1.5 Primary Gain 3.0 5000 10000 15000 5000 10000 15000 Time [ms]... -
Page 38: Figure 4-11. Tuning Runs Showing The Effect Of Adjusted Proportional Trim Example Parameter Values
Released Manual 26758 CPC-DX Current to Pressure Converter Tuning runs showing the effect of example parameter values are shown below. Dynamic Tuning Example Dynamic Tuning Example Primary Gain 3.0 Primary Gain 3.0 Proportional Trim 1.0 Proportional Trim 1.5 5000 10000... -
Page 39: Figure
Released Manual 26758 CPC-DX Current to Pressure Converter Tuning runs showing the effect of example parameter values are shown below. Dynamic Tuning Example Dynamic Tuning Example Primary Gain 3.0 Primary Gain 3.0 Proportional Trim 1.5 Proportional Trim 1.5 Integral Trim 1.0 Integral Trim 0.6... - Page 40 Released Manual 26758 CPC-DX Current to Pressure Converter Tuning runs showing the effect of example parameter values are shown below. Dynamic Tuning Example Dynamic Tuning Example Primary Gain 3.0 Primary Gain 3.0 Proportional Trim 1.5 Proportional Trim 1.5 Integral Trim 0.6 Integral Trim 0.6...
-
Page 41: Figure 4-14. Low Llc Parameter - Sluggish Response, Visible Controlled Unit Position Variation, And Unit-To-Unit Performance Difference
Released Manual 26758 CPC-DX Current to Pressure Converter Dynamic tuning example; Primary Gain 3.0 Proportional Trim 1.5 Integral Trim 1.5 LLC CPC-II Unit #1; 0 LLC CPC-II Unit #2; 0 2000 4000 6000 8000 10000 12000 Time [ms] Demand Signal... -
Page 42: Online Change-Out Of A Pressure Gauge
Released Manual 26758 CPC-DX Current to Pressure Converter Dynamic tuning example; Primary Gain 3.0 Proportional Trim 1.5 Integral Trim 1.5 LLC CPC-II Unit #1; 20 LLC CPC-II Unit #2; 18 2000 4000 6000 8000 10000 12000 Time [ms] Demand Signal... -
Page 43: Figure 4-18. Pressure Gauge Untightening From Adapter
Released Manual 26758 CPC-DX Current to Pressure Converter Do not unscrew only pressure gauge without adapter (with flat wrench SW 11 mm or SW 14 mm) when system is pressurized - pressurized oil may leak and contact hot surfaces. There is a risk of... -
Page 44: Chapter 5. Repair And Troubleshooting
CPC converters be sent to a Woodward authorized service center for clean and test Replacement kits for sections of the CPC-DX skid are available from a Woodward authorized distributor for your local stock that enable you to have the security and immediate response to a service need. -
Page 45: Troubleshooting
Released Manual 26758 CPC-DX Current to Pressure Converter Troubleshooting General The following troubleshooting guide will help you isolate trouble with the control circuit board, actuator, wiring, and system problems. Recommend troubleshooting beyond this level ONLY when a complete facility for control testing is available. - Page 46 Released Manual 26758 CPC-DX Current to Pressure Converter Symptom Cause Recommended Action Adjust primary gain and/or proportional trim or Dynamic adjustments not integral trim and/or load leakage compensation optimal. parameter. Cold oil (viscosity too high). Wait until normal temperature is reached...
- Page 47 Check the oil installation and servo valve for rate. leakage Check the fluid for excessive contamination. Non-Symmetric Contamination Replace or add a system filter ahead of the CPC-DX Switching supply. Contact Woodward service. performance between units Using PC Service Tool perform the recommended...
-
Page 48: Chapter 6. Product Support And Service Options
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 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. -
Page 49: Returning Equipment For Repair
All repair work carries the standard Woodward service warranty (Woodward Product and Service Warranty 5-01-1205) on replaced parts and labor. -
Page 50: Replacement Parts
The unit serial number, which is also on the nameplate Engineering Services Woodward offers various Engineering Services for our products. For these services, you can contact us by telephone, by email, or through the Woodward website. Technical Support ... -
Page 51: Technical Assistance
CPC-DX Current to Pressure Converter 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 52: Chapter 7. Asset Management And Refurbishment Scheduling Period
However, to take advantage of related product software and hardware improvements, we recommend that your product be sent back to Woodward or to a Woodward authorized service facility after every five to ten years of continuous service for inspection and component upgrades. -
Page 53: Chapter 8. Long-Term Storage Requirements
Released Manual 26758 CPC-DX Current to Pressure Converter Chapter 8. Long-Term Storage Requirements Units that will not be put into service within twelve months should be packaged for long-term storage as described in Woodward manual 25075. Woodward... -
Page 54: Revision History
Released Manual 26758 CPC-DX Current to Pressure Converter Revision History Changes in Revision B— Updated Declaration of Conformity and Declaration of Incorporation statements Updated Certifications in Regulatory and Compliance Section Changes in Revision A— Updated Declaration of Conformity and Declaration of Incorporation statements... -
Page 55: Declarations
Released Manual 26758 CPC-DX Current to Pressure Converter Declarations Woodward... - Page 56 Released Manual 26758 CPC-DX Current to Pressure Converter Woodward...
- Page 57 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.
Need help?
Do you have a question about the CPC-DX and is the answer not in the manual?
Questions and answers