Woodward ProAct III User manual

Installation and Operation Manual
ProAct™ III / IV
Electric Powered Actuator and Driver
Manual 04127 (Revision B)

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.
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.
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.
This publication may have been revised o
r
updated since this copy was produced. To verify that
you have the latest revision, be sure to check the Woodward website:
www.woodward.com/pubs/current.pdf
The revision level is shown at the bottom of the front cover after the publication number. The latest
version of most publications is available at:
www.woodward.com/publications
If your publication is not there, please contact your customer service representative to get the
latest copy.
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.
To prevent damage to a control system that uses an alternator or batter
y
-charging
device, make sure the charging device is turned off before disconnecting the battery
from the system.
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.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is assumed
by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1994
All Rights Reserved

Manual 04127 ProAct III/IV Actuator/Driver
Woodward i
Contents
ELECTROSTATIC DISCHARGE AWARENESS ..................................................III
CHAPTER 1. GENERAL INFORMATION...........................................................1
CHAPTER 2. DESCRIPTION OF OPERATION...................................................7
Introduction.............................................................................................................7
Electronic Circuits...................................................................................................7
4–20 mA Output Models.........................................................................................8
Actuator Position Signal .........................................................................................8
Actuator ..................................................................................................................8
CHAPTER 3. INSTALLATION........................................................................11
Driver Installation..................................................................................................11
Actuator Installation..............................................................................................11
Actuator Bracket...................................................................................................12
Linkage.................................................................................................................13
Electrical Connections..........................................................................................14
Shielded Wiring ....................................................................................................14
Power Supply .......................................................................................................15
Driver Adjustments...............................................................................................16
Actuator Travel.....................................................................................................17
CHAPTER 4. TROUBLESHOOTING...............................................................19
Introduction...........................................................................................................19
Linkage and Actuator Stroke................................................................................19
CHAPTER 5. SERVICE OPTIONS .................................................................20
Product Service Options.......................................................................................20
Woodward Factory Servicing Options..................................................................21
Returning Equipment for Repair...........................................................................22
Replacement Parts...............................................................................................22
Engineering Services............................................................................................23
How to Contact Woodward...................................................................................23
Technical Assistance............................................................................................24
PROACT III/IV ACTUATOR/DRIVER SPECIFICATIONS...................................25

ProAct III/IV Actuator/Driver Manual 04127
ii Woodward
Illustrations and Tables
Figure 1-1. ProAct Driver Outline Drawing.............................................................3
Figure 1-2. ProAct III Actuator Outline Drawing.....................................................4
Figure 1-3. ProAct IV Actuator Outline Drawing.....................................................5
Figure 1-4. Plant Wiring Diagram...........................................................................6
Figure 2-1. ProAct III and IV Functional Block Diagram.........................................7
Figure 2-2. ProAct III Actuator Cross Section ........................................................9
Figure 2-3. ProAct IV Actuator Cross Section......................................................10
Figure 3-1. Diesel Engine Travel Stops................................................................12
Figure 3-2. Use ProAct Travel Stops for Carburetors ..........................................12
Figure 3-3. Example of Actuator Bracket .............................................................13
Figure 3-4. Wiring to Power Supply......................................................................16
Figure 3-5. ProAct Driver Adjustment Locations..................................................17
Figure 3-6. Tolerance Limits in Driver Setup........................................................18
Table 1-1. ProAct Actuator Specifications..............................................................1
Table 1-2. ProAct Driver Configurations.................................................................1
Table 1-3. ProAct Accessories...............................................................................2

Manual 04127 ProAct III/IV Actuator/Driver
Woodward iii
Electrostatic Discharge Awareness
All electronic equipment is static-sensitive, some components more than others.
To protect these components from static damage, you must take special
precautions to minimize or eliminate electrostatic discharges.
Follow these precautions when working with or near the control.
1. Before doing maintenance on the electronic control, discharge the static
electricity on your body to ground by touching and holding a grounded metal
object (pipes, cabinets, equipment, etc.).
2. 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.
3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam
cups, cup holders, cigarette packages, cellophane wrappers, vinyl books or
folders, plastic bottles, and plastic ash trays) away from the control, the
modules, and the work area as much as possible.
4. 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.
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.

ProAct III/IV Actuator/Driver Manual 04127
iv Woodward

Manual 04127 ProAct III/IV Actuator/Driver
Woodward 1
Chapter 1.
General Information
The ProAct™ III and ProAct IV drivers convert either a 0–200 mA or 4–20 mA
control signal from a Woodward electronic control into a specific actuator
position.
The ProAct drivers require a separate electrical supply of 20–32 Vdc. The supply
must be capable of supplying a sustained 10 A and a peak 20 A for up to two
seconds for both the ProAct III and ProAct IV drivers.
The ProAct III actuator provides up to 14 J (10 ft-lb) of work to move the fuel
setting lever on the engine. The ProAct IV actuator provides up to 27 J (20 ft-lb)
of work. The actuators rotate 75 degrees, and they have position feedback.
Figures 1-1 through 1-3 show the control outline drawings, and Figure 1-4 is the
plant wiring diagram.
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.
Actuator Model Work Output Part Numbe
r
(CW to Max *) Part Numbe
r
(CCW to Max *)
ProAct III
MS connector 14 J (10 ft-lb) 8405-009 8405-011
ProAct III
conduit fitting 14 J (10 ft-lb) 8405-010 8405-012
ProAct IV
MS connector 27 J (20 ft-lb) 8405-013 8405-015
ProAct IV
conduit fitting 27 J (20 ft-lb) 8405-014 8405-016
* “CW [CCW] to Max” refers to the direction that the actuator rotates to increase fuel
when looking at the rotor.
Table 1-1. ProAct Actuator Specifications
Driver
Model
420 mA
Cntrl Signal
0200 mA
Cntrl Signal
420 m
A
Cntrl Signal,
420 mA
Actuator
Pos. Output
0200 m
A
Cntrl Signal,
420 mA
Actuator
Pos. Output
Model III
MS connector 9905-386 9905-387 9905-459 9905-392
Model III
conduit fitting 9905-384 9905-385 N/A N/A
Model IV
MS connector 9905-390 9905-391 9905-461 9905-460
Model IV
conduit fitting 9905-388 9905-389 N/A N/A
Table 1-2. ProAct Driver Configurations

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Description Part Numbe
r
Comments
J1 Mating Connector 5416-460 Driver only
J2 Mating Connector 5416-461 Driver and Actuator
J2 Mating Connector (90°) 1631-639 Driver and Actuator
J3 Mating Connector 203-889 Driver only
ProAct III/IV Connector Kit 8923-188 J1, J2 (2), no J3
Table 1-3. ProAct Accessories

Manual 04127 ProAct III/IV Actuator/Driver
Woodward 3
Figure 1-1. ProAct Driver Outline Drawing
(Conduit version shown; MS connector version has connector plugs)

ProAct III/IV Actuator/Driver Manual 04127
4 Woodward
Figure 1-2. ProAct III Actuator Outline Drawing

Manual 04127 ProAct III/IV Actuator/Driver
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Figure 1-3. ProAct IV Actuator Outline Drawing

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NOTE 1—Mating connectors: J1 (5416-460), J2 (5416-461), J3 (203 889).
NOTE 2—Shielded wires to be twisted pairs with shield grounded at driver end only.
NOTE 3—8, 6, or 4 mm² (8, 10, or 12 AWG) stranded wire. Must be as short as possible.
Maximum actuator wire lengths are shown on page 12.
Figure 1-4. Plant Wiring Diagram

Manual 04127 ProAct III/IV Actuator/Driver
Woodward 7
Chapter 2.
Description of Operation
Introduction
The ProAct™ control system functions by receiving a current signal from a
Woodward electronic governor. The system then sends a pulse width modulated
(PWM) current (–20 A to +20 A) signal to the actuator, modified by signals from a
position feedback, velocity, and current sensor from the actuator (see Figure
2-1).
Figure 2-1. ProAct III and IV 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.
Three potentiometers, accessible when the cover of the driver box is removed,
provide all adjustments to the driver system.

ProAct III/IV Actuator/Driver Manual 04127
8 Woodward
A 25-turn potentiometer (Offset) adjusts the actuator position with a minimum
input signal from the speed control.
A 25-turn pot (Span) adjusts how far the actuator travels when the speed control
signal varies from minimum to maximum. This pot adjusts the maximum position
of the actuator. The Span adjustment range is approximately 40 degrees to 75
degrees.
The Span and Offset adjustments are interrelated. The adjustments may need to
be repeated until the desired actuator travel is achieved.
A one-turn pot (ACT. BANDWIDTH) adjusts how quickly the actuator responds to
a change in signal from the speed control (bandwidth 2–9 Hz).
4–20 mA Output Models
Units which provide a 4–20 mA output proportional to actuator position have two
additional 25-turn potentiometers (Position Span and Position Offset). These
potentiometers adjust the 4–20 mA output to correspond to minimum and
maximum positions of the actuator. The Position Offset adjusts the output at
minimum position to be 4 mA. The Position Span adjusts how much the output
changes with a given actuator position change and is used to adjust the
maximum output current. The adjustments are interrelated and may need to be
repeated until the desired output is achieved.
Actuator Position Signal
The feedback device is located on the closed shaft of the actuator. The device is
a rotary transducer which changes resistance proportional to the location of the
shaft. The device is a non-contacting unit, thereby eliminating most wear
problems. The feedback voltage is approximately 2 Vdc at 0° and 3 Vdc at 75°
(measured from 0 to –).
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 Figures 2-2 and 2-3).

Manual 04127 ProAct III/IV Actuator/Driver
Woodward 9
Figure 2-2. ProAct III Actuator Cross Section
(MS connector plug shown, conduit version has conduit connector)

ProAct III/IV Actuator/Driver Manual 04127
10 Woodward
Figure 2-3. ProAct IV Actuator Cross Section
(MS connector plug shown, conduit version has conduit connector)

Manual 04127 ProAct III/IV Actuator/Driver
Woodward 11
Chapter 3.
Installation
Driver 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 a temperature range of –40 to +70
°C (–40 to +158 °F).
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 instructions in this chapter).
The driver will generate some heat, so surfaces must be open to normal air
movement. No special ventilation is required. The driver must be bolted to a heat
sink of a minimum 0.4 m² (4 ft²) of 3 mm (1/8-inch) mild steel.
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 either the ProAct™
III or ProAct IV 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.
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.

ProAct III/IV Actuator/Driver Manual 04127
12 Woodward
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 3-1).
Figure 3-1. Diesel Engine Travel Stops Figure 3-2. Use ProAct Travel Stops for Carburetors
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 3-2).
The engine must always shut down when the actuator is at the minimum stop.
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 III actuator weighs 11 kg (25 lbs), and the ProAct IV actuator weighs
19 kg (42 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 3-3 provides an illustration of the mounting
bracket.

Manual 04127 ProAct III/IV Actuator/Driver
Woodward 13
Figure 3-3. Example of Actuator Bracket
[When mounting on the bottom of the actuator, torque the attaching bolts to 17 to 18 Nxm
(150 to 160 lb-in).]
Linkage
Proper design and installation of the linkage from the actuator to the engine is
necessary if the unit is to give good control. Do not remove the inertia disk from
the output shaft. It is necessary to achieve steady-state control with low external
inertia loads.
Make sure that the actuator has ample work capacity to control the fuel supply
under maximum load conditions.
Manually stroke the fuel-control linkage from stop to stop as if the actuator were
moving it. The linkage must move freely, without friction, and without backlash.
Lubricate or replace worn linkage or fuel control parts as required.
A light loading spring to minimum fuel is included in the actuator. A positive
shutdown is necessary in the event of a loss of power to the actuator/driver.
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 III actuator's Mass
Moment of Inertia (MMOI) is 0.027 in-lb-sec². The ProAct IV actuator's
MMOI is 0.058 in-lb-sec². The fuel system stops must be adequate to
absorb this MMOI plus the inertia of the linkage without damage.

ProAct III/IV Actuator/Driver Manual 04127
14 Woodward
ProAct III actuator stops are designed to absorb 1.1 J (10 in-lb) of kinetic energy
with 3 degrees overtravel. ProAct IV actuator stops are designed to absorb 2.3 J
(20 in-lb) of kinetic energy with 3 degrees of 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 and
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 a 0.625-36 serration to fit on the ProAct III actuator or 0.750-48 serration to
fit on the ProAct IV actuator.
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° rotation as possible, at least 60°.) 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.
Electrical Connections
External wiring connections and shielding requirements for a typical control
installation are shown in the plant wiring diagram (see Figure 1-4).
Use 8, 6, or 4 mm² (8, 10, or 12 AWG) wire throughout the ProAct circuit. The
total distance from the battery to the driver and from the driver to the actuator
must not exceed the maximum wire length indicated in the following formula:
one-half the battery-wire length plus the actuator wire length must be less than or
equal to 12.2 m.
For example:
actuator wire length (4 mm²) battery wire length (4 mm²)
3.1 m max. 18.2 m max.
6.1 m max. 12.2 m max.
9.1 m max. 6.2 m max.
Actuator wire lengths may be multiplied by 1.6 for 6 mm² (10 AWG) wire.
Actuator wire lengths may be multiplied by 2.5 for 8 mm² (8 AWG) wire.
Shielded Wiring
All shielded cable must be twisted conductor pairs. 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, EMI Control for
Electronic Governing Systems, for more information.