Woodward ProAct II User manual

Product Manual 04176
(Revision G, 8/2015)
Original Instructions
ProAct™ II Electric Powered
Actuator and Driver
Installation and Operation Manual

General
Precautions
Read this entire manual and all other publications pertaining to the work to be
performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions.
Failure to follow instructions can cause personal injury and/or property damage.
Revisions
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
the publications page of the Woodward website:
www.woodward.com/publications
The latest version of most publications is available on the publications page. If
your publication is not there, please contact your customer service representative
to get the latest copy.
Proper Use
Any unauthorized modifications to or use of this equipment outside its specified
mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.
Translated
Publications
If the cover of this publication states "Translation of the Original Instructions"
please note:
The original source of this publication may have been updated since this
translation was made. Be sure to check manual
26455 , Customer Publication
Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.
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
Woodward 1
Contents
WARNINGS AND NOTICES............................................................................3
ELECTROSTATIC DISCHARGE AWARENESS ..................................................4
CHAPTER 1. GENERAL INFORMATION...........................................................5
Introduction.............................................................................................................5
CHAPTER 2. INSTALLATION........................................................................10
Unpacking.............................................................................................................10
Mounting...............................................................................................................10
Actuator Installation..............................................................................................10
Actuator Bracket...................................................................................................12
Electrical Connections..........................................................................................13
Power Supply .......................................................................................................14
Position Feedback Adjustment.............................................................................16
Actuator Travel.....................................................................................................17
CHAPTER 3. DESCRIPTION OF OPERATION.................................................18
Electronic Circuits.................................................................................................18
Actuator Position Signal .......................................................................................19
Actuator ................................................................................................................19
CHAPTER 4. TROUBLESHOOTING...............................................................20
Linkage and Actuator Stroke................................................................................20
CHAPTER 5. TECHNICAL SPECIFICATIONS..................................................21
Power Supply .......................................................................................................21
Actuator Position Feedback..................................................................................21
System Wiring ......................................................................................................21
Input Configurations .............................................................................................22
System Performance............................................................................................22
CHAPTER 6. PRODUCT SUPPORT AND SERVICE OPTIONS...........................24
Product Support Options......................................................................................24
Product Service Options.......................................................................................24
Returning Equipment for Repair...........................................................................25
Replacement Parts...............................................................................................25
Engineering Services............................................................................................26
Contacting Woodward’s Support Organization ....................................................26
Technical Assistance............................................................................................27
PROACT II ACTUATOR/DRIVER SPECIFICATIONS ........................................28
REVISION HISTORY....................................................................................29
DECLARATIONS.........................................................................................30

ProAct II Actuator/Driver Manual 04176
2 Woodward
Illustrations and Tables
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
The following are trademarks of Woodward, Inc.:
ProAct
Woodward

Manual 04176 ProAct II Actuator/Driver
Woodward 3
Warnings and Notices
Important Definitions
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
DANGER—Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
WARNING—Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION—Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
NOTICE—Indicates a hazard that could result in property damage only
(including damage to the control).
IMPORTANT—Designates an operating tip or maintenance suggestion.
Overspeed /
Overtemperature /
Overpressure
The engine, turbine, or other type of prime mover should be
equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.
Personal Protective
Equipment
The products described in this publication may present risks that
could lead to personal injury, loss of life, or property damage.
Always wear the appropriate personal protective equipment (PPE) for
the job at hand. Equipment that should be considered includes but is
not limited to:
Eye Protection
Hearing Protection
Hard Hat
Gloves
Safety Boots
Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.
Start-up
Be prepared to make an emergency shutdown when starting the
engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
property damage.
Automotive
Applications
On- and off-highway Mobile Applications: Unless Woodward's
control functions as the supervisory control, customer should install
a system totally independent of the prime mover control system that
monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
control with possible personal injury, loss of life, or property
damage.

ProAct II Actuator/Driver Manual 04176
4 Woodward
Battery Charging
Device
To prevent damage to a control system that uses an alternator or
battery-charging device, make sure the charging device is turned off
before disconnecting the battery from the system.
Electrostatic Discharge Awareness
Electrostatic
Precautions
Electronic controls contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts:
Discharge body static before handling the control (with power to
the control turned off, contact a grounded surface and maintain
contact while handling the control).
Avoid all plastic, vinyl, and Styrofoam (except antistatic
versions) around printed circuit boards.
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.
Follow these precautions when working with or near the control.
1. Avoid the build-up of static electricity on your body by not wearing clothing
made of synthetic materials. Wear cotton or cotton-blend materials as much
as possible because these do not store static electric charges as much as
synthetics.
2. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
Do not touch any part of the PCB except the edges.
Do not touch the electrical conductors, the connectors, or the
components with conductive devices or with your hands.
When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.

Manual 04176 ProAct II Actuator/Driver
Woodward 5
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 driver comes in two different package configurations: a sealed
aluminum box with conduit fittings for wiring, and a sheet metal box with grommet
holes for wiring. The sealed box is IP56 capable and is designed for skid-
mounted applications. The sheet metal box is designed for skid or control box
mounted applications in an additional enclosure for protection from the elements.
Both units have the same power supply requirements, vibration capability, and
system response.
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.
Input Signal Nominal Input Range
A
ctuator Output fo
r
Input Range Package Configuration Woodward Part Number
5–32 volt
1 kHz PWM
push-pull source
10% to 90%
duty cycle 0% to 100% actuator position IP56 box w/ conduit connectors
See
Application
Note 51499
0 to 200 mA 20 to 160 mA 0% to 100% actuator position IP56 box w/
conduit connectors
4 to 20 mA 4 to 20 mA 0% to 100% actuator position IP56 box w/
conduit connectors

ProAct II Actuator/Driver Manual 04176
6 Woodward
Figure 1-1. Outline Drawing of ProAct II Driver with IP56 Box

Manual 04176 ProAct II Actuator/Driver
Woodward 7
Figure 1-2. Outline Drawing of ProAct II Driver with Sheet Metal Box

ProAct II Actuator/Driver Manual 04176
8 Woodward
Figure 1-3. Outline Drawing of ProAct Actuator

Manual 04176 ProAct II Actuator/Driver
Woodward 9
Figure 1-4. Plant Wiring Diagram

ProAct II Actuator/Driver Manual 04176
10 Woodward
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).
The driver is capable of withstanding the following vibration specifications:
Shock—US Mil Std 810C, M516.2, PL 40G, 11 ms sawtooth
Vibration—Random Vibration 0.04 G²/Hz WGC RV2
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.

Manual 04176 ProAct II Actuator/Driver
Woodward 11
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.
If operating temperature is a concern, contact Woodward for more information.
Fuel Position Stops
Diesel Stops. Diesel installations will generally use the fuel system minimum
and maximum position stops. Diesel engine racks are normally designed to
provide the minimum and maximum stops without binding.
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.

ProAct II Actuator/Driver Manual 04176
12 Woodward
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.
Figure 2-3. ProAct II Mounting Bracket

Manual 04176 ProAct II Actuator/Driver
Woodward 13
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).
Figure 2-4. Preparing Shielded Wiring
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.
4. Remove 6 mm (1/4 inch) of insulation from the inner conductors.
The shield must be considered as a separate circuit when wiring the system. The
shield must be carried through connectors without interruption.
Installations with severe electromagnetic interference (EMI) may require
additional shielding precautions. Contact Woodward Governor Company for
more information.
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.

ProAct II Actuator/Driver Manual 04176
14 Woodward
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.
To prevent possible damage to the control, or poor control
performance resulting from ground loop problems, follow these
instructions.
It is important to set up the ProAct driver in the order that follows.
See Figure 2-7 for the location of potentiometers on the driver box.
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.
Use an insulated screwdriver to make adjustments. Extensive
damage is possible should the high voltages present inside the box
be shorted to elements on the board.

Manual 04176 ProAct II Actuator/Driver
Woodward 15
Figure 2-5. Correct Wiring to Power Supply
Figure 2-6. Incorrect Power Supply Wiring

ProAct II Actuator/Driver Manual 04176
16 Woodward
Figure 2-7. ProAct Driver Adjustment Locations
Position Feedback Adjustment
The driver's position feedback Gain and Offset adjustments normally don't need
to be changed unless you experience feedback values outside the normal
operating parameters of the driver. If the characteristic falls outside the tolerance
limits, adjust System Position FB Gain and Offset as required to get the
characteristic midway between the tolerance limits (see Figure 2-7 for adjustment
locations).
The procedure for adjusting the system position feedback is as follows.
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.

Manual 04176 ProAct II Actuator/Driver
Woodward 17
The adjustment of the system position feedback potentiometers does
not affect the positioning of the actuator relative to the position input
signal, or the response of the actuator to the position input signal.
Reconnect the actuator drive wires.
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.
This procedure must be repeated whenever the actuator or driver is changed.
The Gain and Offset pots are both located on the printed circuit board inside the
driver box.
The actuator position feedback sensor is factory set and should not be adjusted.

ProAct II Actuator/Driver Manual 04176
18 Woodward
Chapter 3.
Description of Operation
The ProAct control system functions by receiving a position command signal
from a Woodward electronic governor. The system then sends a pulse width
modulated current (–12 A to +12 A) signal to the actuator, modified by signals
from a position feedback, velocity, and current sensor from the actuator (Figure
3-1).
Figure 3-1. ProAct II Functional Block Diagram
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.