Woodward CPC-II User manual

CMM-03001 REVISION A
01/2022
Component Maintenance Manual
Bronze Level
Product Name: CPC-II
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Table of Contents
1.GENERAL INFORMATION .................................................................................................................................................... 5
INTRODUCTION............................................................................................................................................................................... 5
1.1Regulatory Compliance.......................................................................................................................................................... 5
1.2Warnings and Notices ............................................................................................................................................................ 6
1.3Electrostatic Discharge Awareness ........................................................................................................................................ 7
1.4List of Woodward Literature ................................................................................................................................................... 9
1.5List of Required Hardware or Materials................................................................................................................................ 10
1.6Woodward Required Software ............................................................................................................................................. 10
1.7General Instructions ............................................................................................................................................................. 11
2.PRESSURE TRANSDUCER REPLACEMENT .................................................................................................................... 12
2.1Replacement Kit Description................................................................................................................................................ 12
2.2Disassembly Procedure ....................................................................................................................................................... 12
2.3Assembly Procedure ............................................................................................................................................................ 17
2.4Verification & Calibration...................................................................................................................................................... 21
3. SPRING REPLACEMENT........................................................................................................................................................... 25
3.1Replacement Kit Description................................................................................................................................................ 25
3.2Disassembly Procedure ....................................................................................................................................................... 26
3.3Assembly Procedure ............................................................................................................................................................ 30
3.4Verification & Calibration...................................................................................................................................................... 36
4.REVISION HISTORY ........................................................................................................................................................... 39
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Table of Figures
Figure 2-1. External Components – Retention Clamp............................................................................................................................ 13
Figure 2-2. Cover and Valve Housing O-ring ......................................................................................................................................... 14
Figure 2-3. Wire Tie and Transducer Wires Location............................................................................................................................. 15
Figure 2-4. Tool Setup and Pressure Transducer Location ................................................................................................................... 16
Figure 2-5. Prepare and Install Pressure Transducer ............................................................................................................................ 17
Figure 2-6. Properly Installed Transducer Wires in Terminal Block of PC Board ................................................................................... 18
Figure 2-7. PCB Wire Tie and Valve Housing Cover Installation ........................................................................................................... 19
Figure 2-8. Retention Clamp Installation................................................................................................................................................ 20
Figure 2-9. Service Port Connections .................................................................................................................................................... 21
Figure 2-10. CPC-II Service Tool Analog Input Settings Screen............................................................................................................ 22
Figure 2-11. CPC-II Service Tool Overview Screen............................................................................................................................... 23
Figure 2-12. 10Bar and 25Bar CPC-II Version Tables ........................................................................................................................... 24
Figure 3-1. Spring Cover and Spring Assembly ..................................................................................................................................... 26
Figure 3-2. Spring Cover Removal......................................................................................................................................................... 27
Figure 3-3. Spring Assembly Removal – Final Steps............................................................................................................................. 28
Figure 3-4. O-ring Removal.................................................................................................................................................................... 29
Figure 3-5. Control Shaft and Plate Assembly Screw Locations ............................................................................................................ 30
Figure 3-6. Spring Tang Highlight and Marking of Return Spring and Housing...................................................................................... 31
Figure 3-7. Spring Assembly Installation and Orientation ...................................................................................................................... 32
Figure 3-8. Installation of Spring Assembly Screws ............................................................................................................................... 33
Figure 3-9. Installation of Final Spring Assembly Screws and O-ring .................................................................................................... 34
Figure 3-10. Installation of Spring Assembly Cover ............................................................................................................................... 35
Figure 3-11. Service Port Connections .................................................................................................................................................. 36
Figure 3-12. CPC-II Service Tool Analog Input Settings ........................................................................................................................ 37
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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.
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1. GENERAL INFORMATION
INTRODUCTION
This Component Maintenance Manual is intended to be used by customers and Woodward authorized service centers for repair or service of
the CPC-II.
Bronze level service is preventative and routine maintenance that requires little to no specialized tooling, testing, or calibration procedures to
maintain product between normal overhaul intervals. The manual is written with the assumption that the reader has access to the product
manual and other Woodward documents referenced within this document.
1.1 Regulatory Compliance
The CPC-II is subject to safety regulatory certifications. See product manual 26488 for additional details. The service center performing the
work on the CPC-II must not alter the construction such that the certifications are invalidated.
FLAMEPATH
Disassembly of product will require handling of critical components used in a Zone 1 flameproof and/or Division 1
explosion proof design. Special care must be taken as to not damage these parts as it could compromise the method of
protection for the product. Flamepaths are identified in drawing 9989-7001.
Threaded Flamepaths: Care must be taken during handling and assembly to not damage threads. Inspect for damage to threads, which includes
but is not limited to, galling, cross threading, and excessive wear. Damage to threads and/or thread fit can compromise the effectiveness of the
method of protection. If any damage is discovered, contact Woodward prior to reinstallation or assembly into system.
Radial and Flat Joint Flamepaths: Care must be taken during handling and assembly to not damage the flat surface of the flamepath. Inspect
primary surface and mating surface for damage, including but not limited to, scratches, porosity, and marks due to impact. Damage to these
surfaces can compromise the effectiveness of the method of protection. If any damage is discovered, contact Woodward prior to reinstallation or
assembly into system.
Repair of Flamepaths: The flameproof joints are not intended to be repaired. Return to Woodward for repair and maintenance if joints are
damaged.
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Explosion Hazard —Do not connect or disconnect while circuit is live unless area is known to be non-hazardous.
Substitution of components may impair suitability for Class I, Division 1 or 2, or Zone 2 applications.
1.2 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.
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.
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.
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Disconnect
Power Supply
Before performing maintenance, always disconnect power and any hazardous voltages that may be connected. Follow all
appropriate lockout/lockdown procedures.
Hazards due to insufficiently qualified personnel!
If unqualified personnel perform work on or with the control of unit, hazards may arise which can cause serious injury
and substantial damage to property. Therefore, all work must be carried out by appropriately qualified personnel.
Remove pressure before servicing. Failure to do so may damage the CPC-II and/or cause injury.
1.3 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.
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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, as 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. After removing the old PCB
from the control cabinet, immediately place it in the antistatic protective bag.
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1.4 List of Woodward Literature
Required Documents
Product Manual 26615 – CPC-II Current-to-Pressure Converter with Enhanced
D
y
namics
Installation Drawin
g
9999-1728-1 - Kit, CPC-II, Pressure Transducer
Installation Drawin
g
9999-1728-6 - Kit, CPC-II, Sprin
g
Drawin
g
9989-7001 - Flamepath Drawin
g
Reference Documents
Manual 26455 – Customer Publication Cross Reference and Revision
Status & Distribution Restrictions
Product Manual 26758 – CPC-DX Current to Pressure Converter
Dual Transfer Skid
CPC-II Unit replacement
Procedure 26824
–
CPC-DX Current to Pressure Converter
Dual Transfer Skid, CPC-II Unit replacement procedure
Manual 82715 – Guide for Handling and Protection of Electronic
Controls, Printed Circuit Boards, & Modules
Woodward software-download section website (www.woodward.com/searchpublications).
If unable to access Woodward documentation, refer to contact list at the end of this manual.
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1.5 List of Required Hardware or Materials
Special Tool(s) 8923-2376 - KIT - CPC II, TOOLS FOR CUSTOMER'S REPLACEMENT
Torque Wrenches Torque wrench
(
capable of 100 in-lbs
)
Torque Screwdriver(s) 35
–
39 in-lbs
(
3.9 - 4.4 Nm
)
T
y
pe: slotted; Tip Size: .250 in
Basic Tools/Lubricants
Screwdriver; Type: slotted; Tip Size: .250 in
Screwdriver; Type: slotted; Tip Size: .079 in
Steel bar (approx. 8 X 50 mm, 1 meter long (3/8 x 2 inch; 3.3 ft. long)
O-ring pick
Diagonal cutting pliers
Oil absorbent pads/mats
Lifting strap (minimum capacity 100 lbs / 50 kg)
Isopropanol cleaning fluid
GN paste (Molykote DX Paste or similar)
Dry lubricant MS-143-H (optional)
Petroleum jelly for O-ring lubrication
PC computer with Woodward PC Service Tool installed
Measuring Equipment Pressure
g
au
g
e
(
ran
g
e from 0 to 30 bar
)
Tools are not contained within the replacement kit. Please order separately.
1.6 Woodward Required Software
9927-1885 – CPC-II PC Service Tool
Woodward website (www.woodward.com/software)
.
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1.7 General Instructions
Review the CMM and installation drawing before starting the replacement to be sure that all necessary tools are available and instructions are clear.
Check the replacement parts kit to verify all replacement parts listed in the installation drawing are present. For questions, contact Woodward.
Sort all parts for easy assembly.
If not all parts are used, the unit or units must be inspected for completeness.
Contact Woodward if an error is found during the replacement process.
Clean the exterior of the CPC-II by hand prior to disassembly to prevent dirt and debris from contaminating the interior.
O-rings:
oUse the correct tool to install or remove O-rings. If using a protective cone on small O-rings, lubricate the O-ring and slide it onto the part being
sure it does not twist.
oIf a cone is not used on large O-rings, use a pick under the O-ring to lift it onto the part until it is in the desired location.
Retaining rings:
oDuring installation, be careful not to over-extend or over-compress a retaining ring. All retaining rings should be installed with the sharp edge
away from the pressure. Inspect all installed retaining rings to be sure they have been properly seated, fit snugly, and do not rotate freely on the
parts they are installed on or in.
Helicoils:
oTo prevent damage to mid-grip helicoils, install screws at a slow speed. DO NOT USE A HIGH-SPEED TOOL. Stainless steel screws MUST be
lubricated with an anti-seize lubricant before turning them into mid-grip helicoils or aluminum parts.
Disassembly:
oParts that have been disassembled and will be reused must be inspected closely for damage and replaced if necessary. Parts that have been
disassembled should be kept in a clean container such that they can be readily identified against this procedure, reference drawings, or visual
aids for proper reassembly.
Screws:
oAll screws loosen with counterclockwise direction. In other situations, the direction will be specified.
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2. PRESSURE TRANSDUCER REPLACEMENT
2.1 Replacement Kit Description
The purpose of this procedure is to show the correct sequence and method of pressure transducer replacement. Verify pressure value on nameplate to
ensure proper kit is used.
- CPC-II Model - 10 bar, Replacement Kit: 8935-1205-10
- CPC-II Model - 25 bar, Replacement Kit: 8935-1205-25
2.2 Disassembly Procedure
Before starting any disassembly, connect to the CPC-II using the PC Service Tool. Download and save a .wset file from
the service unit. Store the settings file on the PC in a place where you can find it for later use.
.
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A. Remove Cover Retention Clamp.
Figure 2-1. External Components – Retention Clamp
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B. Remove cover (in case of difficulties, place
the steel bar (1 m long) between the two
cover lugs).
THREADED FLAMEPATH
Refer to Section 1.1 for specific
instructions.
C. Remove old O-ring from valve housing.
Figure 2-2. Cover and Valve Housing O-ring
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D. Cut wire tie to free transducer wiring
bundles.
E. Disconnect the three transducer wires from
the terminal block on the PC board using
slotted screwdriver (screwdriver size .079
in).
Figure 2-3. Wire Tie and Transducer Wires Location
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F. Remove pressure transducer (use tool
1012-6806).
G. Clean machined sealing surfaces using
isopropanol cleaning fluid.
H. Visually inspect all surfaces. Ensure there is
no damage to sealing surfaces, hydraulic
fluid contamination, or corrosion that is not
easily removed with 30 Micron lapping film
or chemical cleaning. Inspect all threads for
damage or galling.
Figure 2-4. Tool Setup and Pressure Transducer Location
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2.3 Assembly Procedure
A. Check the replacement parts kit to verify all
replacement parts listed in the installation
drawing are present.
B. Lubricate O-ring with petroleum jelly and
install on pressure transducer.
C. Apply GN paste to the threads of pressure
transducer.
D. Install pressure transducer into the valve
housing with tool 1012-6806 and torque
transducer to 80 ±8.0 lb-inches.
Figure 2-5. Prepare and Install Pressure Transducer
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E. Cut shield wire down to the insulation on
the pressure transducer. Trim red, black,
and green wires to have 1/4 inch (6mm) of
wire exposed.
F. Terminate the three wires of the pressure
transducer to the wire terminal block of the
PC board as shown in picture. Perform wire
pull test to ensure proper installation of
cables.
Do not over tighten screws on wire
terminals. Doing so may result in
permanent damage.
Figure 2-6. Properly Installed Transducer Wires in Terminal Block of PC Board
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G. Install new wire tie on PCB cover to secure
pressure transducer cable.
Note: An extra wire tie is included in the parts
kit.
THREADED FLAMEPATH
Refer to Section 1.1 for specific
instructions.
H. Lubricate new cover O-ring with petroleum
jelly and install onto the housing.
I. Apply GN paste (or MS-143H if available) to
the threads of the valve housing cover.
Install cover by rotating clockwise and hand
tighten to snug only by placing a 1-meter
bar between the two cover lugs as shown in
the picture below. Cover should tighten
almost completely by hand with no tools.
Figure 2-7. PCB Wire Tie and Valve Housing Cover Installation
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J. Apply GN paste to the threads of the screw
and secure the clamp by installing the
screw through clamp into valve housing.
Torque the screw to 37 ±2 lb-inches.
Figure 2-8. Retention Clamp Installation
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