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Summary of Contents for Woodward CPC-DX
- Page 1 Individual CPC-II Converter Replacement Procedure 26824 (Revision NEW) Original Instructions CPC-DX Current to Pressure Converter Dual Transfer Skid, Individual CPC-II Converter Replacement Procedure...
- Page 2 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.
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Page 3: Table Of Contents
NLINE UNIT REPLACEMENT System preparation to unit replacement............... 10 CPC-II Unit disassembly from the CPC-DX Skid ..........16 Electrical wires disassembly from removed CPC-unit (failed) ......24 New CPC-II Unit hardware Installation procedure ..........29 ... - Page 4 Figure 1-6. Electrical Terminal Box, wiring diagram ..........7 Figure 2-1. Saving CPC-II Settings File (creating back-up)........9 Figure 2-2. Unit In Control verification using CPC-DX pressure gauges..... 10 Figure 2-3. Unit In Control verification using CPC-DX pressure gauges ..... 10 ...
- Page 5 Figure 6-2. CPC-DX health link (orange switches) in run position and secured with switching locks (white piece)............ 36 Figure 6-3. CPC-DX with applied electrical power – green LED illuminate..37 Figure 6-4. Loading the Settings File to the CPC-II device........37 ...
- Page 6 Replacement Procedure is a guideline that is dependent upon user- supplied configuration and dynamic setting data. Because of the variability of end applications, Woodward makes no warranty, express or implied, as to the suitability of this procedure for any given “live” installation.
- Page 7 The supply pressure isolation valve Overspeed / Overpressure and the control pressure isolation valve should always be closed prior to closing the drain line. Never disconnect redundancy linkage between CPCs when both units are powered. Woodward...
- Page 8 Battery Charging Device It is recommended when performing the removal of a CPC-II converter from the CPC-DX skid that the isolation valves be secured with appropriate locks and tags, in accordance with the installation sites safety procedures.
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Page 9: Electrostatic Discharge Awareness
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. Follow these precautions when working with or near the control. - Page 10 Manual 26824 CPC-II Unit Replacement Procedure 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). For proper operation and safety, ensure the safety ground is properly terminated to a proper earth ground.
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Page 11: Chapter 1. General Information
Chapter 1. General Information Definitions and used abbreviations CPC-DX – Current to Pressure Converter Dual Transfer Skid CPC-II – Current to Pressure Converter Master / Slave – The unit designated as the Master has yielded control to the other unit (Slave) by link between the two CPC-IIs. The Unit designated as the Master will take control during CPC-DX startup. -
Page 12: List Of Woodward Required Software
Oil absorbent pads / mats Others Lifting strap (minimum capacity 100 lbs / 50 kg) Cable Tie Removal Tool PC computer with Woodward PC Service Tool installed beam (approx. 40x100 mm, 1 meter long (2x4 inch; 3.3 ft. long)) Woodward... -
Page 13: Introduction
Manual 26824 CPC-II Unit Replacement Procedure Introduction The CPC-DX is a complete packaged and tested assembly which consists of two Woodward current-to-pressure converters (CPC-II’s) connected together to a single manifold with all interconnect piping, gauges and wiring included and factory tested. -
Page 14: Figure 1-2. Cpc-Dx Installation Drawing, Front View
Manual 26824 CPC-II Unit Replacement Procedure Figure 1-2. CPC-DX Installation Drawing, Front view. Figure 1-3. CPC-DX Installation Drawing, Top view. Woodward... -
Page 15: Figure 1-4. Cpc-Dx Installation Drawing, Customer Interface View
Manual 26824 CPC-II Unit Replacement Procedure Figure 1-4. CPC-DX Installation Drawing, customer interface view. Woodward... -
Page 16: Figure 1-5. Cpc's Wiring Diagram
Manual 26824 CPC-II Unit Replacement Procedure Figure 1-5. CPC’s wiring diagram Woodward... -
Page 17: Figure 1-6. Electrical Terminal Box, Wiring Diagram
Manual 26824 CPC-II Unit Replacement Procedure Figure 1-6. Electrical Terminal Box, wiring diagram Woodward... -
Page 18: Chapter 2. Online Cpc-Ii Unit Replacement
All site safety procedures are observed. The environment surrounding the CPC-DX skid must be ventilated to a non-hazardous combustion level before removing the CPC-II cover or CPC-DX electrical terminal box cover or performing any other steps below. -
Page 19: Figure 2-1. Saving Cpc-Ii Settings File (Creating Back-Up)
To create a new settings file from CPC-II: Using PC Service Tool go to the Settings tab, from pull down menu select “Save from Device to File” and save to an appropriate folder on your computer. See Woodward manual 26615 for more details. -
Page 20: System Preparation To Unit Replacement
Not In Control or Failed should indicate a lower or zero (0) pressure. Figure 2-2. Unit In Control verification using CPC-DX pressure gauges. As shown in figure 2-3 below, the unit on the right (CPC 2) is in control and the unit on the left (CPC 1) is not in control. -
Page 21: Figure 2-4. Unit In Control Verification Using Cpc-Dx Pressure Gauges
B. Check indication in control room which unit is in control (discrete output 2 for CPC-II must be configured as in control / not in control status). C. Use a switching device (e.g. switch relay - not provided with the CPC-DX assembly) to designate master for the unit currently keeping control. -
Page 22: Figure 2-6. Power Supply Input Connections
Manual 26824 CPC-II Unit Replacement Procedure For proper operation and safety, ensure which unit have to be shut down. Wrong action can cause turbine shut down and in some cases serious damage. Figure 2-6. Power Supply Input Connections Woodward... -
Page 23: Figure 2-7. Isolation Valve Open / Closed Lever Position
Figure 2-7. Isolation valve OPEN / CLOSED lever position Figure 2-8. Control Isolation valve CLOSED and locked-out with padlock (lock not provided with the CPC-DX unit) Additionally valve position OPEN/CLOSED could be verified by markings on valve locking plate (see figure 2-9.). -
Page 24: Figure 2-10. Supply Isolation Valves Closed And Locked-Out With Padlock
Manual 26824 CPC-II Unit Replacement Procedure Figure 2-10. Supply Isolation valves CLOSED and locked-out with padlock (not provided with CPC-DX unit) During replacement procedure close and lock – out the drain port in case of positive back pressure. Never close the drain line when supply pressure is... -
Page 25: Figure 2-11. Cpc-Dx Installation Drawing, Drain Ports Location
Manual 26824 CPC-II Unit Replacement Procedure Figure 2-11. CPC-DX Installation Drawing, Drain ports location Woodward... -
Page 26: Cpc-Ii Unit Disassembly From The Cpc-Dx Skid
When you disconnect CPCs health link, the operating CPC will indicate Redundancy Fault alarm: Redundancy Fault A) Open the CPC-DX Electrical Terminal B) Verify if all wire ends and terminals are Box unscrewing 4 (four) screws using properly marked, if not, complete it screwdriver (Type: Phillips;... - Page 27 15 and 16 >7 Running CPC-II Unit # 2 20 and 19 <3 When CPC 2 is shut down (unit to be replaced) Running CPC-II Unit #1 15 and 16 < 3 Shutdown CPC-II Unit #2 20 and 19 >7 Woodward...
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Page 28: Figure 3-1 Cpc-Ii Voltage Measurement And Verification
TWIN - Terminals system (terminals #15; and 20). Upper screw is used to hold foreground wire, lower screw is used to hold background wire, see Figure 3-2 below. Figure 3-2 TWIN - Terminals system handling. See electric diagram shown on Figure 1.5 and figure 1.6. Woodward... -
Page 29: Figure 3-4. Unscrew A Conduit Nut From Electrical Terminal Box Fitting (Ccw Direction)
Example how to attach lifting strap to lift CPC-II unit – see figures 3-5, -6, -7. Heavy object - approximately 49 lbs (22 kg). To avoid injury use lifting aids and proper lifting techniques when removing and replacing Do not lift or handle the CPC-II by any conduit. Woodward... -
Page 30: Figure 3-5. Lifting Strap Installation
Manual 26824 CPC-II Unit Replacement Procedure Figure 3-5. Lifting strap installation. Figure 3-6. Lifting strap properly installed. Figure 3-7. Lifting strap properly installed (CPC-II unit on the CPC-DX hydraulic manifold). Woodward... -
Page 31: Figure 3-8. Long Socket Wrench
Use a long socket wrench 2.5 – 2.7 inch (63 – 69 mm) to unscrew 4 bolts (CCW direction). Access to the bolt from the bottom of the CPC-DX hydraulic manifold. Hex socket size 8 mm. Typical wrench shape is shown on picture below. -
Page 32: Figure 3-10. Cpc-Ii Mounting Bolts Unscrewing (Ccw Direction)
CPC-II mounting bolts, stop and wait until system can be taken off line. Be prepared to use a clean lint free oil absorbent cloth to clean up the spilled oil. Figure 3-11. Oil spillage from removed CPC-II unit. Woodward... -
Page 33: Figure 3-12. Fitting With Installed Plastic Plug
Manual 26824 CPC-II Unit Replacement Procedure Figure 3-12. Fitting with installed plastic plug. Figure 3-13. CPC-DX manifold with secured hydraulic passages after CPC-II unit removal (shown yellow plastic plugs not provided with the CPC-II unit) Figure 3-14. CPC-II unit removed from CPC-DX assembly. -
Page 34: Electrical Wires Disassembly From Removed Cpc-Unit (Failed)
To unscrew CPC-II cover (CCW direction) place a 1 m bar between the two cover lugs. Figure 4-2. Loosening CPC-II cover with bar. Verify if all wire ends and terminals are properly marked, if not, complete it according to Figure 1-5. CPCs, wiring diagram and figure 1-6. Electrical Terminal Box, wiring diagram. Woodward... -
Page 35: Figure 4-3. Cpc-Ii Terminal Blocks View (Cpc-Ii Cover Removed)
Figure 4-3. CPC-II terminal blocks view (CPC-II cover removed). A. Unscrew 4 (four) screws using slotted screwdriver; Tip Size 3.5 X 0.6 Figure 4-4. CPC-II terminal blocks 4 (four) mounting screws localization (CPC-II cover removed). Figure 4-5. Unscrewing 2 (two) CPC-II terminal blocks (CCW direction). Woodward... -
Page 36: Figure 4-6. Cpc-Ii Wire Blocks Pulling Out
Manual 26824 CPC-II Unit Replacement Procedure B. Remove wire block (gently pull out using screwdriver). Figure 4-6. CPC-II wire blocks pulling out. A. Carefully cutout cable ties using Cable Tie Removal Tool. Figure 4-7. CPC-II cable ties cutout. Woodward... -
Page 37: Figure 4-8. Cpc-Ii Ground Wire Unscrewing
Use screwdriver Type Slotted; Tip Size 3.5 X 0.6 mm (CCW direction). Figure 4-9. CPC-II wires removal from terminal block. D. Unscrew a nut, wrench type: Open End; Size: 1.5 in (CCW direction). Figure 4-10. CPC-II conduit nut unscrewing. Woodward... -
Page 38: Figure 4-11. Cpc-Ii Cable And Conduit Removal
Manual 26824 CPC-II Unit Replacement Procedure E. Gently pull out cable from CPC-II housing. Do not pull out the wiring from the conduit! Figure 4-11. CPC-II cable and conduit removal. Woodward... -
Page 39: New Cpc-Ii Unit Hardware Installation Procedure
A. Use electrical tape and cable tie to pull cable through CPC conduit entry. B. Isolation tape and cable tie C. Wires tape wrapping E. CPC cable ready to install D. Cable tie fixing with isolation type to conduit F. CPC cable installation Woodward... - Page 40 Tip Size 3.5 X 0.6 mm. Torque wires clamp screw in terminals to 5.3-7 lbf-in (0.5-0.6 Nm), CW direction. Install two (2) terminal blocks. Use screwdriver Type Slotted; Tip Size 3.5 X 0.6 mm. Torque 4 (four) screws to 5.3-7 lbf-in (0.5-0.6 Nm) CW direction. Woodward...
- Page 41 Manual 26824 CPC-II Unit Replacement Procedure J. Install GND wire. Use screwdriver Type: Phillips; Tip Size: PH 3. Torque to 3.7 lbf-ft (5.1 Nm) CW direction. K. Secure wires with wire ties. Woodward...
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Page 42: Figure 5-1. New Sealing O-Rings Installed On Hydraulic Manifold
Make sure that supply and control isolation valves are closed during installation of the CPC-II unit. Open and close all valves slowly. This will help prevent creating any hydraulic disturbances in the system. Figure 5-1. New sealing O-rings (3 pcs) installed on hydraulic manifold Woodward... -
Page 43: Figure 5-2. Cpc-Ii Wires Inside Electrical Terminal Box
Use a long hex wrench 2.5 – 2.7 inch (63-69 mm) to tighten 4 (four) bolts (CW direction). Access to the bolt from the bottom of the CPC-DX manifold. Hex socket size 8 mm. Typical wrench shape is shown on picture below. -
Page 44: Figure 5-4. Cpc-Ii Mounting Bolts View (Bottom Of The Hydraulic Manifold)
Tighten the conduit nuts to 100-128 lbf-ft (136 – 174 Nm). Use open end style wrench, size 1 1/2 in (CW direction). Figure 5-6. CPC-II conduit nut tightening (CW direction). Double check the wiring connections before applying power. Make sure that all wires are connected to the proper terminals and tightened correctly. Woodward... -
Page 45: Figure 5-6. Cpc-Ii Wires Installation
Figure 1-6. (Electrical Terminal Box, wiring diagram). Use torque screwdriver to install wires in terminals, Type: Slotted; Tip Size: 0.6 x 3.5 mm. Torque to 5.3 – 7.0 lbf-in (0.6 – 0.8 Nm) CW direction. Figure 5-6. CPC-II wires installation. Woodward... -
Page 46: New Cpc-Ii Unit Software Settings Loading Procedure
PCs or laptops with USB ports rather than serial ports, a USB-to-serial converter is required. An approved converter can be obtained from Woodward P/N 8928-1151. Figure 6-1. CPC-II with installed RS-232 connection cable. Figure 6-2. CPC-DX health link (orange switches) in run position and secured with switching locks (white piece). Woodward... -
Page 47: Figure 6-3. Cpc-Dx With Applied Electrical Power - Green Led Illuminate
The green LED illuminate when electrical power is applied. Start the PC Service Tool and download the appropriate settings file from step into new CPC-II unit. Figure 6-3. CPC-DX with applied electrical power – green LED illuminate. When CPC-II connection is established with Service Tool, download the appropriate settings file (previously created) into new CPC-II unit (please refer to User Manual 26615). -
Page 48: Figure 6-5. Basic Parameters Verification
Make sure that Dynamic Performance Parameters match (comparing Unit Not In Control to Unit In control). Only the Load Leakage Parameters could cud have different value – is specific for each unit. (only the Load Leakage Parameters could not match) Woodward... -
Page 49: Figure 6-6. Basic Parameters Verification
Point 4. – Setpoint Fault condition is annunciated be red LED indicator. Figure 6-6. Basic parameters verification. Operate the CPC-II unit in Manual Mode by setting the setpoint to the minimum control pressure (See PC Service Tool tab “Performance Trend and Manual Operation”). Parameter: Manual Control Settings Mode: Enabled Woodward... -
Page 50: Figure 6-7. Manual Control Mode Enabled
Manual 26824 CPC-II Unit Replacement Procedure Figure 6-7. Manual Control Mode Enabled. Woodward... -
Page 51: Figure 6-8. Isolation Valve Open / Closed Lever Position
CPC-II Unit Replacement Procedure Make sure that drain isolation valves is open before opening supply isolation valve located on the CPC-DX unit. Never open the supply line when drain line is closed on the CPC unit, otherwise the control output pressure can increase suddenly and cannot be controlled by the input setpoint. -
Page 52: Figure 6-9. Cpc-Dx Unit With All Isolation Valves In Closed Position
Manual 26824 CPC-II Unit Replacement Procedure Figure 6-9. CPC-DX unit with all isolation valves in CLOSED position If necessary adjust Primary Gain of the replaced unit at the midpoint of the control range for rapid control response with minimal overshoot. Some overshoot is permissible as it is necessary for displacement of the servo. -
Page 53: Figure 6-11. Performance Verification On Performance Trend Chart
B. Check performance by switching between the midpoint and the low point of the control range. Typically the performance will be more stable at this operating point if tuned properly for high pressure and mid pressure performance. Figure 6-12. Performance verification on Performance Trend chart Woodward... -
Page 54: Figure 6-13. Manual Control Mode Disabled
Figure 6-13. Manual Control Mode Disabled. Verify if the replaced CPC-II unit has pressure offset at the same level as the unit in control (default is 0.8 bar). See PC Service Tool tab Redundancy Overview Parameter: In Slave Mode Setpoint is Decreased by: Woodward... -
Page 55: Figure 6-14. Pressure Offset Value Verification Between Cpc-Ii Units
Manual 26824 CPC-II Unit Replacement Procedure Figure 6-14. Pressure offset value verification between CPC-II units. Woodward... -
Page 56: Figure 6-15. Pc Service Tool Communication Disconnection With Cpc-Ii
CPC’s. Close PC Service Tool connection clicking Disconnect (see Figure 6-16) and disconnect RS-232 interface cable from CPC-II communication port. Figure 6-15. PC Service Tool communication disconnection with CPC-II. Figure 6-16. RS-232 cable disconnection from CPC-II communication port. Woodward... -
Page 57: Figure 6-17. Cpc-Ii Cover Tightening
Figure 6-17. CPC-II cover tightening. Install and torque the locking clamp screw to 35-39 lbf-in (3.9 - 4.4 Nm) in CW direction. Use flat torque screwdriver Type: Slotted; Tip Size 6.5 X 1.2 Figure 6-18. CPC-II locking clamp tightening. Woodward... -
Page 58: Chapter 3. Product Service Options
A Recognized Engine Retrofitter (RER) is an independent company that does retrofits and upgrades on reciprocating gas engines and dual-fuel conversions, and can provide the full line of Woodward systems and components for the retrofits and overhauls, emission compliance upgrades, long term service contracts, emergency repairs, etc. -
Page 59: Replacement Parts
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 60: Technical Assistance
CPC-II Unit Replacement Procedure 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 61: Revision History
Manual 26824 CPC-II Unit Replacement Procedure Revision History Changes in Revision NEW— Initial release Woodward... - Page 62 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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