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Woodward CPC-II Product Manual

Woodward CPC-II Product Manual

Current-to-pressure converter with enhanced dynamics
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Released
Product Manual 26615
(Revision R, 8/2020)
Original Instructions
CPC-II
Current-to-Pressure Converter
with Enhanced Dynamics
Installation and Operation Manual

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Summary of Contents for Woodward CPC-II

  • Page 1 Released Product Manual 26615 (Revision R, 8/2020) Original Instructions CPC-II Current-to-Pressure Converter with Enhanced Dynamics 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

    HAPTER NSTALLING AND UNNING THE ERVICE Making the Hardware Connection ....................... 36 Locating and Installing the CPC-II Service Tool ..................37 System Display Scaling ..........................37 CD Program Installation ..........................38 Running the CPC-II Service Tool ........................ 42 5. U PC M ..
  • Page 4 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Product Service Options ..........................89 Returning Equipment for Repair ......................... 90 Replacement Parts ............................91 Engineering Services ..........................91 Contacting Woodward’s Support Organization ................... 91 Technical Assistance ..........................92 10. A ......
  • Page 5 Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Illustrations and Tables Figure 1-1. Isometric Front View of the CPC-II ................... 10 Figure 1-2. Example System Schematic ..................... 11 Figure 1-3. Example Functional Diagram (CPC electronics) ..............13 Figured 2-1. CPC-II Small Signal Step Response (Typical) ............... 16 Figure 2-2.
  • Page 6 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Table R-1. Details of Table 1, IEC 60079-1 (Ed. 6) ..................8 Table 1-1. CPC-II Models Included In This Manual ..................11 Table 2-1. Electrical Specifications ......................15 Table 2-2. Hydraulic Specifications ......................15 Table 2-3.

  • Page 7: Warnings And Notices

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics 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 8: 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 9: Regulatory Compliance

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Regulatory Compliance European Compliance for CE Marking EMC Directive: Declared to Directive 2014/30/EU of the European Parliament and of the Council of 26 February 2014 on the harmonization of the laws of the Member States relating to electromagnetic compatibility (EMC) ATEX –...

  • Page 10: Special Conditions For Safe Use

    Connect external safety ground terminal to earth ground. Conduit seals must be installed within 46 cm (18 inches) of the conduit entry when the CPC-II is used in Class I, Division 1 hazardous locations. Conduit Entries: 3/4 inch NPT thread.
  • Page 11 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics La substitution de composants peut rendre ce matériel inacceptable pour les emplacements de Classe I, applications Division 2 ou Zone 2. Risque d'explosion Woodward...

  • Page 12: Chapter 1. General Information

    For severe applications, or those with safety requirements, fully redundant CPC-II models are available. When used in a dual-redundant arrangement, the Slave CPC-II will take control if it detects that a fault has occurred in the Master. In this situation, Discrete Output 2 will change state to "In Control".

  • Page 13: Figure 1-2. Example System Schematic

    9907-1254 Not Currently Available Supply 25 bar Control 25 bar Ask for "Woodward CPC-DX Dual Transfer Skid" for a fully redundant unit with two CPCs mounted on the manifold with transfer valve (PNs 8918-116, 8918-118). Construction The main elements of the CPC-II include: •...

  • Page 14: Printed Circuit Board

    Actuator The CPC-II uses a rotary limited angle torque (LAT) actuator. The permanent magnet rotor is directly coupled to the hydraulic valve. The position of the rotor is measured by a solid-state integrated circuit on the PCB, which detects the direction of the sensing magnet on the shaft.

  • Page 15: Figure 1-3. Example Functional Diagram (Cpc Electronics)

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Figure 1-3. Example Functional Diagram (CPC electronics) The power supply section performs the EMI filtering on the (18 to 32) V (dc) input voltage and generates controlled voltage for several electronic sub-systems. The power supply system is monitored for proper operation.
  • Page 16 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics The actuator position control loop and pressure control loop are monitored to ensure tracking. If the tracking diagnostics detect a mismatch in either valve position or pressure, the annunciation of a fault condition displays on the appropriate discrete output.

  • Page 17: Chapter 2. Specifications

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Chapter 2. Specifications Table 2-1. Electrical Specifications Connections Removable terminal suitable for (0.8 to 3) mm² / (12 to 18) AWG stranded wire Cable Entries Entry via two ¾”-14 NPT threaded ports suitable for North American conduit or...

  • Page 18: Performance

    Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Recommended Fluid Mineral or synthetic based oils may be used. Woodward oil recommendations per manual 25071. A serviceable external supply filter with a rating of (24 to 40) µm nominal β75 must be provided. ISO 20/16 Fluid cleanliness or better is recommended for optimum reliability.

  • Page 19: Figure 2-2. Pressure Responses

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics CPC-II Large Signal Pressure Response (Typical) Pressure Setpoint Pressure Feedback Time (Seconds) Figure 2-2. Pressure Responses CPC-II Flow Capacity Differential Pressure - Bar (P1 to Pc or Pc to Drain) Figure 2-3. Maximum Flow Capacity Table 2-3.
  • Page 20 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Table 2-4. Environmental Ambient Temperature (–40 to +85) °C Humidity 95% relative humidity Oil Temperature Range (15 to 70) °C Max. Surface Temperature 85 °C Vibration US MIL-STD 810F, M514.5A, Cat. 4 (0.015 G²/Hz, 10 Hz to 500 Hz, 1.04...

  • Page 21: Figure 2-3A. Installation Drawing

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Figure 2-3a. Installation Drawing Woodward...

  • Page 22: Figure 2-3B. Installation Drawing

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Figure 2-3b. Installation Drawing Woodward...

  • Page 23: Figure 2-3C. Installation Drawing

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Figure 2-3c. Installation Drawing Woodward...

  • Page 24: Figure 2-3D. Installation Drawing

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Figure 2-3d. Installation Drawing Woodward...

  • Page 25: Chapter 3. Installation

    Receiving Instructions Packing the CPC-II at the factory protects it from damage during shipping; however, careless handling during shipment can result in damage. If you discover any damage to the CPC-II, immediately notify both the shipping agent and Woodward. Unpacking Instructions Carefully unpack the CPC-II and remove it from the shipping container.

  • Page 26: Mounting Instructions

    The CPC-II is attached (clamped) to the adapter block by four M10x1.5 screws. The screws should engage the threads of the CPC-II for a minimum of 16 mm for a reliable and solid mounting. The interface should be designed with counterbores to accept face seal O- rings.

  • Page 27: Hydraulic Connections

    Make Supply pressure, Control pressure, and Tank/Drain connections on the CPC-II via a face seal shown in Figure 3-1. S, C, and T are marked on the fluid interface of the CPC-II. A provided O-ring face seal interface is a feature of the manifold plate.

  • Page 28: Electrical Connections

    2 A at 24 V (dc) continuously, with a peak of 5 A for two seconds. The CPC-II is not equipped with input power switches. Some means of switching input power to the CPC- II supply must be provided for installation and servicing.

  • Page 29: Figure 3-2. Wiring Diagram

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Figure 3-2. Wiring Diagram CPC Input Power Protective Internal Device Power To Customer Reverse Voltage Power Supply Protection Supply Motor Driver. Figure 3-3. Power Supply Input Connections Woodward...

  • Page 30: Figure 3-4. Correct And Incorrect Wiring To Power Supply Input

    Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Follow good wiring practices although the CPC-II is protected against input voltage transients, The following drawing illustrates correct and incorrect wiring methods to the power supply. Figure 3-4. Correct and Incorrect Wiring to Power Supply Input Wiring Requirements: •...

  • Page 31: Figure 3-5. Recommended Wiring Strain Relief

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Wiring Strain Relief Tie down points and ratcheting tie wraps are provided to secure the wiring to the top of the PCB. This helps prevent wire strain from being transmitted to the connection at the terminal block and to keep the wiring from chafing on the cover when tightening and under vibration.

  • Page 32: Analog Inputs

    CPC-II Current-to-Pressure Converter / Enhanced Dynamics Analog Inputs There are two analog inputs to the CPC-II. One is dedicated to the setpoint input. For applications where reliability is critical, the second analog input can be configured for a redundant setpoint input, or for a redundant pressure sensor input.

  • Page 33: Figure 3-7. Manual Test Adjustment (Shown With Cover In Place)

    CPC-II Current-to-Pressure Converter / Enhanced Dynamics Manual Stroke Potentiometer An internal potentiometer is provided for manual testing and verification of the CPC-II during commissioning or troubleshooting. The potentiometer is accessible under the cap on the front of the unit. Figure 3-7. Manual Test Adjustment (shown with cover in place)

  • Page 34: Analog Outputs

    Analog Outputs The analog output of the CPC-II is in the form of a (4 to 20) mA output and can drive load resistances from 0 up to 500 ς . This output can be configured to perform one of many different tasks, such as reporting, pressure feedback, pressure setpoint, and internal valve position.

  • Page 35: Discrete Inputs

    CPC-II Current-to-Pressure Converter / Enhanced Dynamics Discrete Inputs The CPC-II has two discrete inputs. External power is not necessary for these inputs as the isolation is provided internally. The discrete inputs have an internal pull-up resistor and are inverted at the processor, such that an open circuit is the passive low state.

  • Page 36: Discrete Outputs

    Discrete Output 2: If CPC-II is in simplex mode, it is defaulted for alarm indication. It can also be configured to annunciate master status, unit in control status, any alarm, or any alarms or shutdowns. If...
  • Page 37 When wired using cable and cable glands, the gland fitting must meet the same hazardous locations criteria as the CPC-II. Follow all installation recommendations and special conditions for safe use that are supplied with the cable gland. The cable insulation must have a temperature rating of at least 85 °C and 10 °C above the maximum ambient and fluid temperature.

  • Page 38: Chapter 4. Installing And Running The Pc Service Tool

    RS-232 connection between the computer and the CPC-II. The physical connection can be made in one of two ways: connect to the CPC-II at the DB9 connector located next to the terminal block, or, if the cover must be in place during operation (hazardous locations), the RS-232 line can be routed through the gland fitting or conduit hub and connected at the J2 terminal block.

  • Page 39: Locating And Installing The Cpc-Ii Service Tool

    Woodward provides an approved converter P/N 8928-1151) Note that the CPC-II Service Tool Software will check for the above two components. If the CD is used, these will be loaded automatically off the CD. If the CPC-II Service Tool is downloaded from the Woodward Software Internet site, the user will be prompted to install these components from the site.

  • Page 40: Cd Program Installation

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics CD Program Installation To start the installation, insert the BCD85270 CD into the laptop or PC disc tray and use the RUN icon from the START menu. Use the BROWSE tab to locate the following file and press “OK”. The setup.exe file is located under the 9927-1885.CD directory.

  • Page 41: Figure 4-4. Tookit Software License Agreement

    Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics This window will then be followed by the license agreement for Woodward ToolKit if it is not already installed. Review the agreement and then press “Accept”. Figure 4-4. TooKit Software License Agreement The installation and configure process will now begin.

  • Page 42: Figure 4-6. Service Tool Setup Wizard

    CPC-II Current-to-Pressure Converter / Enhanced Dynamics Once Framework and ToolKit are installed, the CPC-II Service Tool will next be installed. The following screen will appear: (Note that this will be the first screen if the computer already has Framework 3.5 and ToolKit 3.6 installed.)

  • Page 43: Figure 4-8. Service Tool Installation Screen

    Press “Finish” to complete the setup. You can check the Launch box if you want to run the Service Tool when you press “Finish”. Figure 4-9. Service Tool Installation Complete Screen The CPC-II Software is now installed and is ready to run. Woodward...

  • Page 44: Running The Cpc-Ii Service Tool

    Running the CPC-II Service Tool With the Installation complete, the Service Tool can be run by selecting Start followed by All Programs -> Woodward and the finding the CPC-II Service Tool item. Also, the CPC-II Service Tool shortcut is available on the desktop: Once the Service Tool is running, you will get a screen similar to the one below.

  • Page 45: Figure 4-11. Service Tool Communications Connected Screen

    CPC-II Current-to-Pressure Converter / Enhanced Dynamics A screen similar to the one below will appear while the laptop attempts to connect to the CPC-II. If the screen remains in the connecting mode below, there is a problem in establishing communication. This could be a problem with the cable connections or possibly with selecting the wrong network (see above).

  • Page 46: Chapter 5. Using The Pc Monitoring Tool For Performance Assessment And Tuning

    Assessment and Tuning Introduction After installation, settings in the CPC-II must be set for proper operation using the PC Service Tool. For newer computers without serial ports, a USB to serial converter is required. Woodward provides an approved converter P/N 8928-1151. The following section includes information for proper verification of settings.
  • Page 47 Alarm possible. The cause of alarm conditions should be determined and corrected to prevent damage to the turbine, CPC-II, or other auxiliary equipment. Alarm is annunciated with yellow LED indicator. Green LED indicator is illuminated when condition is active.

  • Page 48: Common Header

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Common Header Common Header is a part of service tool screen which is displayed on each monitoring page. It displays information about associated firmware version and present readings of the most important properties of the CPC-II.

  • Page 49: Home

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Home Figure 5-4. Service Tool Home Screen Screen when first starting the Service Tool. Cannot access other screens until Home communications have been established. Woodward...

  • Page 50: Pc Service Tool Overview Screen

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics PC Service Tool Overview Screen Figure 5-5. PC Service Tool Overview Screen Analog Input 1 The current values received at each analog interface are displayed. These Analog Input 2 values can be compared to the values sent at the control, or by a multi-meter to Analog Output verify proper calibration.

  • Page 51: Performance Trend And Manual Operation

    The Primary Gain is set higher when the downstream load (piston) has more swept volume. The default value is 1.5. Dither Amplitude of the CPC-II dither, in % of CPC-II movement. Dither is helpful when Amplitude the load has high friction. The default value is 0.
  • Page 52 Input the pressure setpoint value or adjust using the up/down arrows. Setpoint Manual The CPC-II can be operated using the Manual Stroke Adjustment Potentiometer Potentiometer when it is enabled. This function can also be disabled if this feature is not desired for Stroke a particular application.
  • Page 53 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Silt Buster The silt buster (patent pending) is a short, symmetrical impulse which moves the Settings valve momentarily in the bypass direction, spilling oil from the control passage to bypass and flushing any silt built up on the control shaft. After the short impulse in the bypass direction, the internal valve is quickly moved above the control point to restore the amount of fluid lost during flush.

  • Page 54: Redundancy Overview

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Gain Switching This adjustment sets the width of a window above the minimum and below the maximum range settings. When operating within this “Edge Range”, the Out of Range gain values are used. This allows the 0% range setting to be set slightly Threshold below the valve cracking point, thus ensuring full valve closure.
  • Page 55 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Faults Diagnostics associated with the redundant functions are shown in the faults group. Setpoint Spread The difference between the two setpoint signals exceeds the maximum Fault spread threshold. To modify the maximum spread threshold, see configuration in Chapter 6.
  • Page 56 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics LSS : Low Signal Selection. Using the lower of the two signals Setpoint Signals HSS: High Signal Selection. Using the higher of the two signals Spread Configuration Disabled: The spread fault will not be annunciated. Failure of a single input will be detected if it falls outside of the Low or High Range limits of the analog input.

  • Page 57: Analog Input Settings

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Analog Input Settings The analog input settings including scaling and diagnostics levels are displayed from this screen. The values of the current operational and diagnostic settings are also displayed. To modify these settings, see section configuration in Chapter 6.
  • Page 58 0.2 bar) See Figure 5-4. The 0% range mA setting can also be set to values other than 4 mA to compensate for slight variations in analog output accuracy from the control, or if using the CPC-II in a split range operation with multiple servos. See Chapter 6 on configuration for more details.

  • Page 59: Analog And Discrete Output Settings

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Analog and Discrete Output Settings Figure 5-9. PC Service Tool Analog/Discrete Output Settings Analog Output Function The configured function of the analog output is displayed. Present Reading The value at the input of the control is displayed in mA.
  • Page 60 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Internal Valve Position Readback Scaling This adjustment sets the minimum internal valve position 0% of Range Settings corresponding to 4 mA. Typically this is 0%. The default value is 0%. This adjustment sets the minimum internal valve position 100% of Range Settings corresponding to 20 mA.

  • Page 61: Pressure Demand Linearization Settings

    CPC-II Current-to-Pressure Converter / Enhanced Dynamics Pressure Demand Linearization Settings The CPC-II provides a linearization function for actuator/linkage systems with a non-linear relationship of control pressure to position or control pressure to flow rate. This linearization can be used to generate a desired curvature between the input setpoint and the delivered control pressure.

  • Page 62: Detailed Diagnostics

    CPC-II Current-to-Pressure Converter / Enhanced Dynamics Detailed Diagnostics The current state of the CPC-II’s internal diagnostics are displayed on this page. In addition, the value of a few key parameters which can be used for troubleshooting are also displayed. Resetting of all active and logged faults is performed from this page.
  • Page 63 Setpoint The setpoint for the position of the internal valve, computed by the CPC-II’s control algorithm as necessary for pressure control. 0 is full bypass, 100% is full supply. Normal control is approximately 50%. Actual The actual position of the internal valve in %.
  • Page 64 Limit device. Note: The ratings are dependent upon the part number of the CPC-II. Correct the input range settings, See Chapter 6 on configuring the CPC-II. Operating Range Below The range limit settings exceed the lower range limit of the Limit device.
  • Page 65 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Feedback Faults Flash This group includes diagnostics, which monitor the pressure Flash Code Group 4 Code feedback sensor(s) . These faults relate to performance or calibration of the pressure feedback device.
  • Page 66 Redundant Link Input Failure This applies to redundant units only. The pulse train from the other CPC-II cannot be detected. Check the redundant link wiring between the two CPC-IIs. Check the configuration of the unit on the Redundancy Overview screen.

  • Page 67: Chapter 6. Configuring The Cpc-Ii Using The Pc Service Tool

    Configuring the CPC-II Using the PC Service Tool Introduction After installation, certain settings in the CPC-II must be set for proper operation using the PC Service Tool. The following section includes information for proper verification of settings. You may modify the settings described in this section using the settings editor, an off-line configuration tool.

  • Page 68: Dynamic Performance Settings

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Once the desired changes have been made, upload them into the control by selecting the Load Settings File to Device option from the pull down menu. Figure 6-3. Loading the Settings File to the Device Dynamic Performance Settings Figure 6-4.
  • Page 69 The Primary Gain is set higher when the downstream load (piston) has more swept volume. The default value is 1.5. Dither Amplitude of the CPC-II dither, in % of CPC-II movement. Dither is helpful when Amplitude the load has high friction. The default value is 0.

  • Page 70: Configure Redundancy

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Gain Switching This adjustment sets the width of a window above the minimum and below the maximum range settings. When operating within this “Edge Range”, the Out of Range gain values are used. This allows the 0% range setting to be set slightly Threshold below the valve cracking point, thus ensuring full valve closure.
  • Page 71 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics When the 2 analog input is used for redundant setpoint, the signal Setpoint Inputs conditioning behavior can be selected. Choose the desired signal selection criteria from the pull-down window. Signal Selection LSS –...
  • Page 72 When using redundant units, the setpoint Redundant Pair Settings of the designated Slave CPC-II is reduced when in Not In Control mode so that the two units do not interact. The amount of pressure reduction is tunable.

  • Page 73: Analog Input Configuration

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Analog Input Configuration Figure 6-6. Analog Input Settings Page Analog Input 1 and 2 These settings control the minimum level of control pressure. The pressure setting value should correspond to a pressure just slightly below that required to reach the minimum travel of the servo.

  • Page 74: Personal Injury

    CPC-II Current-to-Pressure Converter / Enhanced Dynamics The CPC-II allows the setpoint range to be set slightly wider than the physical stroke pressure range of the servo. This enables the valve to be firmly seated in the fully closed position. Since operating below the servo range increases the system “hydraulic stiffness”...

  • Page 75: Analog And Discrete Output Configuration

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Analog and Discrete Output Configuration Figure 6-8. PC Service Tool Analog/Discrete Output Configuration Analog Output The analog output can be configured to output the following parameters: Pressure Setpoint Function Pressure Feedback...

  • Page 76: Pressure Demand Linearization Settings

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Internal Valve Position Readback Scaling 0% of Range This adjustment sets the minimum internal valve position corresponding to Settings 4 mA. Typically this is 0%. 100% of Range This adjustment sets the maximum internal valve position corresponding to Settings 20 mA.

  • Page 77: Figure 6-10. Pc Service Tool Demand Linearization Configuration

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics You may adjust the parameters of the Pressure Demand Linearization to compensate for non-linear linkage or spring characteristics in the servo system. The linearization function can be enabled or disabled from the settings Enabled editor.

  • Page 78: Configure Alarms And Shutdowns

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Configure Alarms and Shutdowns Figure 6-10. PC Service Tool Diagnostics Settings Editor A Latched fault will hold the designated behavior including the status of the discrete output until the fault is reset from the PC service tool.
  • Page 79 CPC-II Current-to-Pressure Converter / Enhanced Dynamics If the box in the Shutdown/Alarm column is set to "S", the detection of this diagnostic condition will result in shutdown of the CPC-II. If it is set to "A", Shutdown/Alarm the detection will result in annunciation of the condition on the alarm contact.
  • Page 80 Contact Woodward for further instructions if this diagnostic is active. For redundant units only. The pulse train from the other CPC-II cannot be detected. Check the Redundant Link redundant link wiring between the two CPC-IIs. Check the configuration Input Fault of the unit on the Redundancy Overview screen.

  • Page 81: Explosion Hazard

    Set-up/Checkout Procedure Verify that the hydraulic and electrical connections are correct, according to Chapter 3. Confirm that the hydraulic and electrical power to the CPC-II is turned off. Remove the top cover of the CPC-II. Take care not to damage the cover seal, the cover surface, the threads, or the CPC-II surface while removing or replacing the cover.

  • Page 82: Dynamic Adjustments And Calibration

    Connect a calibrated pressure gauge to the control pressure line, in order to measure output pressure. Apply electrical power to the CPC-II. The green LED will illuminate and begin flashing when the unit is ready for operation.
  • Page 83 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Make sure the control is in the shutdown mode (4 mA to 20 mA input to the CPC-II is below 2 mA). Verify the following: • The servo is at the minimum stop.

  • Page 84: Figure 6-11. Expected Dynamic Performance

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Figure 6-11. Expected Dynamic Performance 8. Step the valve position between 40% and 60% a couple of times to verify proper tuning of the Primary gain. If the valve takes a long time to settle out (e.g. the valve is “oscillating”) increase the Integral trim.
  • Page 85 16. The pulse period can be increased if silt accumulation is heavy or decreased if little silt accumulation is present. However, extremely dirty oil quality will eventually have adverse effects on the CPC-II and servo system. Replace the system filter if the Silt Buster pulse period must be set to very frequent intervals.
  • Page 86 If the threads are cleaned, reapply a small amount of dry lubricant to the threads. Take care not to damage the cover seal, the cover surface, the threads, or the CPC-II surface while removing or replacing the cover. Explosion Hazard Damage to sealing surfaces may result in moisture ingress, fire, or explosion.

  • Page 87: Chapter 7. Repair And Troubleshooting

    Please do not remove or alter the nameplate as it bears important information which may be necessary to service or repair the unit. Return for Repair Instruction Should the CPC-II need to be returned for repair, attach a tag on the unit. Include the following information on the tag: •...
  • Page 88 Fluid lines incorrectly installed. Check fluid connections. Contamination within control. Check the fluid for excessive contamination. Replace or add a system filter ahead of the CPC-II supply. Increase the frequency of the Silt Buster impulse. Contact Woodward service. Slow dynamics Dynamic adjustments not Adjust primary gain and/or proportional trim or optimal.
  • Page 89 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Problem Cause Remedy Internal CPC-II oil Pressure sensor is loose, O- Re-torque the pressure sensor. leakage ring is damaged. Replace O-ring. Excessive wear or damage of Replace CPC-II and Adjust Control System: valve shaft seals.

  • Page 90: Chapter 8. Replacing Older Cpcs And Non-Woodward Converters With The New Cpc-Ii

    Contact your local Woodward Sales office or distributor for more information. Some adapter kit plates are made with raw carbon steel. Once CPC-II unit and its mounting plate is installed, coat the raw carbon steel plate with anti-rust oil that is suitable for the working environment.

  • Page 91: Chapter 9. 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 92: 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 93: 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 94: Technical Assistance

    CPC-II Current-to-Pressure Converter / Enhanced Dynamics 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 95: Chapter 10. 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 96: Chapter 11. Long-Term Storage Requirements

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Chapter 11. 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 97: Revision History

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Revision History Changes in Revision R— • Updated ATEX and IECEx certifications in Compliance Section • Removed INMETRO Declaration • Replaced Declarations Changes in Revision P— • Updated ATEX and IECEx certifications in Compliance Section •...
  • Page 98 Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Changes in Revision A— • Updated Regulatory Compliance information • Added note to use manual 26448 for older CPC-II • Updated outline drawings • Added new photos and screen shots • Updated/expanded Chapters 4, 5, & 6 •...

  • Page 99: Declarations

    Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Declarations Woodward...
  • Page 100 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Woodward...
  • Page 101 Released Manual 26615 CPC-II Current-to-Pressure Converter / Enhanced Dynamics Woodward...
  • Page 102 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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