Product Manual 04176 (Revision G, 8/2015) : Proact™ Ii Electric Powered Actuator and Driver
Product Manual 04176 (Revision G, 8/2015) : Proact™ Ii Electric Powered Actuator and Driver
Product Manual 04176 (Revision G, 8/2015) : Proact™ Ii Electric Powered Actuator and Driver
(Revision G, 8/2015)
Original Instructions
This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
Revisions the publications page of the Woodward website:
www.woodward.com/publications
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.
Manual 04176
Copyright © Woodward 1997–2015
All Rights Reserved
Manual 04176 ProAct II Actuator/Driver
Contents
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Figure 1-1. Outline Drawing of ProAct II Driver with IP56 Box ...............................6
Figure 1-2. Outline Drawing of ProAct II Driver with Sheet Metal Box ...................7
Figure 1-3. Outline Drawing of ProAct Actuator .....................................................8
Figure 1-4. Plant Wiring Diagram ...........................................................................9
Figure 2-1. Diesel Engine Travel Stops ................................................................12
Figure 2-2. Carburetor Travel Stops .....................................................................12
Figure 2-3. ProAct II Mounting Bracket ................................................................12
Figure 2-4. Preparing Shielded Wiring .................................................................13
Figure 2-5. Correct Wiring to Power Supply .........................................................15
Figure 2-6. Incorrect Power Supply Wiring ...........................................................15
Figure 2-7. ProAct Driver Adjustment Locations ..................................................16
Figure 3-1. ProAct II Functional Block Diagram ...................................................18
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Chapter 1.
General Information
Introduction
The ProAct II driver converts either a 0–200 mA, 4–20 mA, 4–13 mA, 11–20 mA,
PWM, or a 0–5 V control signal from a Woodward electronic control into a
specific actuator position. The driver provides a feedback of 0.5–4.5 V
corresponding to actuator position.
The ProAct II drivers require a separate electrical supply of 20–32 Vdc. The
supply must be capable of providing a sustained 6 A and a peak 12 A for up to
two seconds for the driver.
The ProAct actuator provides up to 5.4 J (4.0 ft-lbs) transient and 2.7 J (2.0
ft-lbs) steady state of work to move the fuel-setting lever on the engine. The
actuators have position feedback.
Engine stability and response are set by the controlling device, not by the
actuator and driver. Follow the instructions for the controlling device while setting
up the engine control system.
The following configurations are available for the position command input.
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Manual 04176 ProAct II Actuator/Driver
Figure 1-2. Outline Drawing of ProAct II Driver with Sheet Metal Box
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Chapter 2.
Installation
Unpacking
Be careful when unpacking the electronic driver. Check the driver for signs of
damage, such as bent or dented panels, scratches, and loose or broken parts.
Notify the shipper and Woodward if damage is found.
Mounting
The driver box is designed to operate within an ambient temperature range of
–40 to +70 °C (–40 to +158 °F).
If the application has a higher vibration level than specified (0.04 G²/Hz),
vibration isolators must be used to keep the levels below the given levels.
Mount the driver in a location with space for adjustment and wiring access. Do
not expose the driver to sources of radiant heat such as exhaust manifolds or
turbochargers. Mount the driver close enough to the actuator and battery to meet
the wire length requirements (see wiring requirements in Chapter 5).
The driver will generate some heat, so surfaces must be open to normal air
movement. No special ventilation is required.
Ideally, the driver should be mounted flush to the metal side of a control cabinet,
protected from the weather and high humidity, and close to the engine being
controlled. Do not install the driver directly on the engine. The location should
provide protection from high-voltage or high-current devices, or devices which
produce electromagnetic interference. After initial adjustments are completed,
access to the driver will not be required for normal engine operation.
Actuator Installation
Thermal
The actuators are designed for installation on the engine. The actuators will
generate heat, especially when stalled or during other conditions requiring
maximum torque output. Maximum operating temperature for the ProAct II
actuator is 100 °C (212 °F).
The installer must consider the heat conductivity of the installation bracket, and
the operating temperature of the ultimate heat sink to which the bracket will be
attached. Generally the heat transfer abilities of aluminum and low-carbon steel
are better than those of high-carbon steel or stainless steel.
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Manual 04176 ProAct II Actuator/Driver
Uninhibited air flow over the heat-exchanger fins on the side of the actuators will
help control possible heat problems. Keep the fins as clean as possible to
improve heat transfer. Do NOT paint the fins, since this will reduce the heat
transfer efficiency.
The actuator's stops must not prevent the actuator from driving the fuel linkage to
the minimum and maximum positions. The linkage should be designed to use as
much actuator travel as possible, without preventing minimum and maximum fuel
positions (see Figure 2-1).
Gas Engine Stops. Butterfly valves in carburetors will often bind if rotated too far
toward minimum or maximum. For this reason, the stops in the actuator should
be used at both minimum and maximum positions. Note that the stops will allow
up to 3 degrees of additional rotation in both directions during impact (see Figure
2-2).
The engine must always shut down when the actuator is at the minimum stop.
The actuator's maximum slew rate can place stress on fuel system
stops and on the linkage between the actuator and the fuel system.
Maximum actuator speed is 900 degrees per second in both the
increase and decrease fuel directions. The ProAct II actuator's Mass
Moment of Inertia (MMOI, with inertia disc applied) is 3.67*10-3 in-lb-
sec².
ProAct II actuator stops are designed to absorb 1.1 J (10 in-lbs) of kinetic energy
with 3 degrees overtravel. If the actuator travel stops are used, the linkage must
be designed to allow this 3 degree overrun.
Use good rod-end connectors with as little free play as possible. Select rod ends
which will not become loose and which will wear well during the nearly constant
movement associated with precise speed control. Low-friction, long-wearing rod
ends are available from Woodward.
The link connecting the actuator lever to the fuel-control lever must be short or
stiff enough to prevent flexing when the engine is running.
Actuator levers are available from Woodward which allow adjustment of the rod-
end location with respect to the center of the actuator shaft. The lever used must
have the correct interface for the actuator used.
Adjust the location of the rod end on the lever to achieve the desired rotation of
the actuator shaft between minimum and maximum positions. (Use as much of
the 75-degree rotation as possible—at least 60 degrees.) To increase the
amount of rotation, move the rod end closer to the actuator shaft or farther away
from the shaft controlling fuel flow. To decrease the amount of rotation used,
move the rod end farther from the actuator shaft or closer to the shaft controlling
fuel flow.
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Figure 2-1. Diesel Engine Travel Stops Figure 2-2. Carburetor Travel Stops
Actuator Bracket
The actuator may be installed on a bracket which attaches to the base with four
M8x1.25 (0.312-18) screws with a minimum engagement of 16 mm (0.625 inch).
The actuator may be mounted in any attitude. The actuator is weatherproof and
resistant to the corrosive effects of water and salt water. Avoid pressure washing
near the shaft seals.
The ProAct II actuator weighs 6.9 kg (15.23 lbs). The bracket and attaching
hardware must be designed to hold the weight and to withstand the vibration
associated with engine mounting. The bracket must also be designed to provide
a heat sink (heat transfer) from the actuator to the engine block. Figure 2-3
provides an illustration of the mounting bracket.
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Manual 04176 ProAct II Actuator/Driver
Electrical Connections
External wiring connections and shielding requirements for a typical control
installation are shown in the plant wiring diagram (Figure 1-4).
The type and gauge of the wiring used should follow the wire length and type
shown in the System Wiring section of Chapter 5.
Shielded Wiring
All shielded cable must be twisted conductor pairs or triples. Do not attempt to tin
the braided shield. All signal lines should be shielded to prevent picking up stray
signals from adjacent equipment. Connect the shields to the correct pins on the
driver connector or wiring. Do not connect shields to the actuator ground. Wire
exposed beyond the shield should be as short as possible, not exceeding 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 application note 50532, Interference
Control in Electronic Governing Systems, for more information.
Where shielded cable is required, cut the cable to the desired length and prepare
the cable as instructed below (Figure 2-4).
1. Strip outer insulation from BOTH ENDS, exposing the braided or spiral
wrapped shield. DO NOT CUT THE SHIELD.
2. Using a sharp, pointed tool, carefully spread the strands of the shield.
3. Pull inner conductor(s) out of the shield. If the shield is the braided type,
twist it to prevent fraying.
The shield must be considered as a separate circuit when wiring the system. The
shield must be carried through connectors without interruption.
Failure to provide shielding can produce future conditions which are difficult to
diagnose. Proper shielding at the time of installation is required to assure
satisfactory operation of the ProAct control system.
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Power Supply
Power supply output must be low impedance (for example, directly from
batteries).
Run an insulated wire directly from the positive (+) battery terminal to the fuse
and the switch as shown in Figure 2-5, then from the switch to the correct
connection on the driver (see Figure 1-4). Run a second insulated wire directly
from the negative (–) terminal of the battery to the driver. Neither of these
connections needs to be shielded (see Figure 2-5 for correct installation).
Run the power leads directly from the power source to the control. DO NOT
POWER OTHER DEVICES WITH LEADS COMMON TO THE CONTROL. If the
power source is a battery, be sure the system includes an alternator or other
battery-charging device (see Figure 2-6 for incorrect installation).
When the engine is shut down, the driver powers the actuator to the minimum
stop. If the battery charging system is off when the engine is shut down, this will
cause the battery to be drained. In this case, the power to the ProAct must be
turned off with a switch or relay. Any such switch or relay must be interlocking to
prevent starting the engine when power to the actuator is shut off.
Do not use the driver for normal shutdown procedures. All actuator position
commands should come from the control unit, through the driver, to the actuator.
Always hold onto the side of the control box with one hand while
making an adjustment with the other hand. This prevents possible
static damage to parts.
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To set up the driver system feedback, first disconnect the actuator drive wires at
the control (DO NOT disconnect the actuator position feedback wires). Power up
the system with the actuator disconnected from the linkage but with the inertia
disk in place. DO NOT START THE ENGINE AT THIS TIME.
The actuator can be manually moved between minimum and maximum fuel,
based on actuator stops. Adjust the System Position FB (feedback) Gain and
Offset potentiometers until the output at the terminals is within the desired
specification. The nominal voltages are 0.5 V at minimum fuel and 4.5 V at
maximum fuel.
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Manual 04176 ProAct II Actuator/Driver
Actuator Travel
The driver's Gain and Offset adjustments normally don't need to be changed
unless you experience difficulty getting the actuator to travel full stroke. If the
characteristic falls outside the tolerance limits, adjust Position Command Gain
and Offset as required to get the characteristic midway between the tolerance
limits (see Figure 2-7 for adjustment locations).
To set up the driver and actuator, power up the system with the actuator
disconnected from the linkage but with the inertia disk in place. DO NOT START
THE ENGINE AT THIS TIME.
Vary the signal into the position input to the driver and observe actuator angle.
Adjust the Position Command Gain and Offset potentiometers to achieve the
desired relationship (see Figure 2-7). Failure to make this adjustment correctly
may result in the inability to shut off fuel or the inability to reach full-fuel position.
After this adjustment is made, re-install linkage, coupling, etc., to the engine.
The actuator position feedback sensor is factory set and should not be adjusted.
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Chapter 3.
Description of Operation
Electronic Circuits
All circuits in the ProAct driver are solid state and are not serviceable in the field.
The printed circuit board is manufactured by Woodward to provide maximum
tolerance to temperature and vibration.
Four potentiometers, accessible when the cover of the driver box is removed,
provide all adjustments to the driver system.
A 25-turn pot (Position Command Gain) adjusts how far the actuator travels
when the speed control signal varies from minimum to maximum.
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Manual 04176 ProAct II Actuator/Driver
A 25-turn pot (Position Command Offset) adjusts the offset of the actuator travel
when the speed control signal varies from minimum to maximum.
A 25-turn pot (System Position Feedback Gain) adjusts the system position
feedback gain as the actuator varies from minimum to maximum.
A 25-turn pot (System Position Feedback Offset) adjusts the system position
feedback offset as the actuator varies from minimum to maximum.
Actuator
The rotary design of the ProAct actuators gives 75 degrees of shaft rotation to
position fuel controls. The actuators apply torque in both directions. Torque is
proportional to the current supplied to the actuator by the driver.
The actuator uses sealed bearings, eliminating the need for maintenance. The
feedback mechanism attaches to the end of the rotor not being used to control
the engine. The device is enclosed in a Ryton housing and is sealed against the
elements. Avoid pressure washing the actuator.
An inertia disc is installed on the actuator output shaft. The disc is necessary for
stable actuator operation with light, low-friction linkages. Do not remove the disc
(see Figure 1-3).
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Chapter 4.
Troubleshooting
Improper engine operation is often the result of factors other than governor
operation. This chapter gives tips about engine problems which can resemble
governor problems. Make sure the engine is operating correctly before making
any changes in the governor.
If possible, isolate the governor from the engine to determine if the problem is
with the governor and not with the engine or the load on the engine.
Fuel supply and injector conditions can also present problems which resemble
governor problems.
On spark-ignited engines, distributor, coil, points, and timing problems can all
cause improper operations which may resemble faulty governor control.
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Chapter 5.
Technical Specifications
Power Supply
The power supply for the ProAct II driver is configured to operate from 20 to 32
Vdc. The minimum current level to be provided by the system will be 6 A dc and
12 A dc for up to two seconds.
System Wiring
The actuator driver is capable of driving the actuator through wiring harnesses of
the following configurations:
The maximum length of the line distance between the battery summed with twice
the distance between the control and the actuator must be less than the distance
in the following chart.
In applications where these maximum line lengths are followed, the worst case
transient current level at elevated actuator temps (100 ºC ambient) will be 57.5%
of the transient limit. This only affects the transient current limits, the steady state
limits will still be 6 A.
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Input Configurations
The following input configurations are available for the position command input.
PWM
The PWM input will accept a 1000±100 Hz input signal of 5 to 32 V peak voltage
(referenced to unit battery ground). The nominal input of 10% to 90% duty cycle
will correspond to 0% to 100% actuator travel (at system calibration
temperature). The position command input will be capable of providing a
common mode input voltage range (unit battery ground referenced) of 0 to 4 V
for all inputs.
0–200 mA
The 0–200 mA input will accept a 0 to 200 mA dc input. The nominal input of 20
to 160 mA will correspond to 0% to 100% actuator travel (at system calibration
temperature). The position command input will be capable of providing a
common mode input voltage range (unit battery ground referenced) of 0 to 4 V
for all inputs.
4–20 mA
The 4–20 mA input will accept a 0 to 20 mA dc input. The nominal input of 4 to
20 mA will correspond to 0% to 100% actuator travel (at system calibration
temperature). The position command input will be capable of providing a
common mode input voltage range (unit battery ground referenced) of 0 to 4 V
for all inputs.
System Performance
The performance of the driver when mated to a ProAct II actuator will be as
follows:
Inertia level
The driver mated to a ProAct II actuator can drive inertial loads not to exceed
5.9*10–3 in-lb-sec². This is specified as un-damped direct inertia.
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Actuator compliance
The actuator compliance will be to reach peak steady-state torque in less than
5% of actuator full travel, external deflection of the actuator from commanded
position for all supply voltages and current levels within the specified power
supply ranges.
Position accuracy
The position accuracy for command to position will be better than 1% of actuator
full travel after the unit has been calibrated to the actuator for gain and offset.
This accuracy is valid at the calibration temperature of the actuator assembly. If
the actuator assembly temperature is different from the calibration temperature,
the position error will be less than 20% over the entire temperature range. The
temperature deviation is a negative tolerance. This means that the unit will drift
such that minimum fuel and maximum fuel is always reachable using the
standard input range. However, the unit may reach minimum or maximum fuel at
input percentages 20% less than (in the case of maximum fuel) or greater than
(in the case of minimum fuel) the nominal range.
System protection
The system contains protection circuitry to prevent damage if the power supply
circuits are connected in reverse polarity. The unit also contains circuitry to
prevent driver and actuator damage if one of the actuator wires is short-circuited
to battery positive or ground, or if one actuator wire is shorted to the other. The
result will be an actuator shutdown during the period of the short circuit. The unit
also contains circuitry to prevent driver and actuator damage if the driver steady-
state current rises above 6 A continuously. The result will be an actuator
shutdown.
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Chapter 6.
Product Support and Service Options
OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
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Manual 04176 ProAct II Actuator/Driver
Replacement/Exchange: Replacement/Exchange is a premium program
designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.
This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard
mechanical products and some of the electronic products in the field. This
program offers you repair service for your products with the advantage of
knowing in advance what the cost will be.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option, with the exception that the unit will be returned to you in “like-
new” condition. This option is applicable to mechanical products only.
When shipping the item(s), attach a tag with the following information:
return number;
name and location where the control is installed;
name and phone number of contact person;
complete Woodward part number(s) and serial number(s);
description of the problem;
instructions describing the desired type of repair.
Packing a Control
Use the following materials when returning a complete control:
protective caps on any connectors;
antistatic protective bags on all electronic modules;
packing materials that will not damage the surface of the unit;
at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
a packing carton with double walls;
a strong tape around the outside of the carton for increased strength.
Replacement Parts
When ordering replacement parts for controls, include the following information:
the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
the unit serial number, which is also on the nameplate.
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Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our
products. For these services, you can contact the Distributor by telephone or by
email.
Technical Support
Product Training
Field Service
Technical Support is available from your equipment system supplier, your local
Full-Service Distributor, or from many of Woodward’s worldwide locations,
depending upon the product and application. This service can assist you with
technical questions or problem solving during the normal business hours of the
Woodward location you contact.
You can also contact the Woodward Customer Service Department at one of the
following Woodward facilities to obtain the address and phone number of the
nearest facility at which you can obtain information and service.
For the most current product support and contact information, please visit our
website directory at www.woodward.com/directory.
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Manual 04176 ProAct II Actuator/Driver
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
Your Name
Site Location
Phone Number
Fax Number
Number of Cylinders
Type of Fuel (gas, gaseous, diesel,
dual-fuel, etc.)
Power Output Rating
Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1
Serial Number
Control/Governor #2
Serial Number
Control/Governor #3
Serial Number
Symptoms
Description
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
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Actuator:
Operating Temperature Range –40 to +100 ºC (–40 to +212 ºF)
Storage Temperature Range –55 to +125 ºC (–67 to +257 ºF)
Shock MS810C, M516.2, Procedure IV, 100 g
Vibration MS810C, M514.2, Proc. VIII, 20 g (10 g in axial
direct.)
Mass Moment of Inertia ProAct II Actuator is 3.67*10-3 in-lb-sec²
(with inertia disc applied)
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Manual 04176 ProAct II Actuator/Driver
Revision History
Changes in Revision G—
Deleted items in Input Configuration table, page 5.
Marked Input Configurations 11–20, 4–13 mA, and 0–5 Volt, as no longer
available. Page 22.
Changes in Revision F—
Revision advanced to coordinate with new installation sheet.
Changes in Revision E—
Updated Actuator Position Signal description (page 15) for new replacement
actuators
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ProAct II Actuator/Driver Manual 04176
Declarations
30 Woodward
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