Woodward CPC-DX User manual

[
Individual CPC-II Converter Replacement Procedure 26824
(Revision NEW)
Original Instructions
CPC-DX
Current to Pressure Converte
r
Dual Transfer Skid,
Individual CPC-II Converter Replacement Procedure

Manual 26824 CPC-II Unit Replacement Procedure
ii Woodward
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 Out-of-date translations are marked with .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 26615
Copyright © Woodward 2011–2015
All Rights Reserved

Manual 26824 CPC-II Unit Replacement Procedure
Woodward iii
Contents
ELECTROSTATIC DISCHARGE AWARENESS ................................................. IX
CHAPTER 1. GENERAL INFORMATION...........................................................1
Definitions and used abbreviations ........................................................................1
List of Woodward Reference Literature..................................................................1
List of Woodward Required Software.....................................................................2
List of Required Hardware or Materials..................................................................2
Introduction.............................................................................................................3
CHAPTER 2. ONLINE CPC-II UNIT REPLACEMENT .........................................8
System preparation to unit replacement...............................................................10
CPC-II Unit disassembly from the CPC-DX Skid .................................................16
Electrical wires disassembly from removed CPC-unit (failed)..............................24
New CPC-II Unit hardware Installation procedure ...............................................29
New CPC-II unit software settings loading procedure..........................................36
CHAPTER 3. PRODUCT SERVICE OPTIONS..................................................48
Replacement Parts...............................................................................................49
Engineering Services............................................................................................49
Contacting Woodward’s Support Organization ....................................................49
Technical Assistance............................................................................................50
REVISION HISTORY....................................................................................51

Manual 26824 CPC-II Unit Replacement Procedure
iv Woodward
Illustrations and Tables
Figure 1-1. CPC-DX main components..................................................................3
Figure 1-2. CPC-DX Installation Drawing, Front view............................................4
Figure 1-3. CPC-DX Installation Drawing, Top view. .............................................4
Figure 1-4. CPC-DX Installation Drawing, customer interface view.......................5
Figure 1-5. CPC’s wiring diagram...........................................................................6
Figure 1-6. Electrical Terminal Box, wiring diagram...............................................7
Figure 2-1. Saving CPC-II Settings File (creating back-up)...................................9
Figure 2-2. Unit In Control verification using CPC-DX pressure gauges. ............10
Figure 2-3. Unit In Control verification using CPC-DX pressure gauges .............10
Figure 2-4. Unit In Control verification using CPC-DX pressure gauges .............11
Figure 2-5. Wiring Connections for Master Designation.......................................11
Figure 2-6. Power Supply Input Connections.......................................................12
Figure 2-7. Isolation valve OPEN / CLOSED lever position.................................13
Figure 2-8. Control Isolation valve CLOSED and locked-out with padlock..........13
Figure 2-9. Open/ Close markings on isolation locking plate...............................13
Figure 2-10. Supply Isolation valves CLOSED and locked-out with padlock.......14
Figure 2-11. CPC-DX Installation Drawing, Drain ports location..........................15
Figure 3-1 CPC-II voltage measurement and verification....................................18
Figure 3-2 TWIN - Terminals system handling.....................................................18
Figure 3-3 Replaced CPC-II wires disconnected inside Electrical Terminal box. 19
Figure 3-4. Unscrew a conduit nut from Electrical Terminal Box fitting (CCW
direction)..........................................................................................19
Figure 3-5. Lifting strap installation.......................................................................20
Figure 3-6. Lifting strap properly installed............................................................20
Figure 3-7. Lifting slug properly installed (CPC-II unit on the CPC-DX hydraulic
manifold)..........................................................................................20
Figure 3-8. Long socket wrench...........................................................................21
Figure 3-9. CPC-II mounting bolts view (bottom of the hydraulic manifold).........21
Figure 3-10. CPC-II mounting bolts unscrewing (CCW direction)........................22
Figure 3-11. Oil spillage from removed CPC-II unit..............................................22
Figure 3-12. Fitting with installed plastic plug.......................................................23
Figure 3-13. CPC-DX manifold with secured hydraulic passages after CPC-II unit
removal............................................................................................23
Figure 3-14. CPC-II unit removed from CPC-DX assembly.................................23
Figure 4-1. Loosening CPC-II cover retaining clamp (CCW direction)................24
Figure 4-2. Loosening CPC-II cover with bar......................................................24

Manual 26824 CPC-II Unit Replacement Procedure
Woodward v
Figure 4-3. CPC-II terminal blocks view (CPC-II cover removed).......................25
Figure 4-4. CPC-II terminal blocks 4 (four) mounting screws localization (CPC-II
cover removed)................................................................................25
Figure 4-5. Unscrewing 2 (two) CPC-II terminal blocks (CCW direction). ..........25
Figure 4-6. CPC-II wire blocks pulling out............................................................26
Figure 4-7. CPC-II cable ties cutout.....................................................................26
Figure 4-8. CPC-II Ground wire unscrewing. .......................................................27
Figure 4-9. CPC-II wires removal from terminal block. ........................................27
Figure 4-10. CPC-II conduit nut unscrewing. .......................................................27
Figure 4-11. CPC-II cable and conduit removal...................................................28
Figure 5-1. New sealing O-rings installed on hydraulic manifold.........................32
Figure 5-2. CPC-II wires inside Electrical Terminal Box ......................................33
Figure 5-3. Long socket wrench...........................................................................33
Figure 5-4. CPC-II mounting bolts view (bottom of the hydraulic manifold).........34
Figure 5-5. CPC-II mounting bolts tightening (CW direction)...............................34
Figure 5-6. CPC-II conduit nut tightening (CW direction).....................................34
Figure 5-6. CPC-II wires installation.....................................................................35
Figure 6-1. CPC-II with installed RS-232 connection cable.................................36
Figure 6-2. CPC-DX health link (orange switches) in run position and secured
with switching locks (white piece)....................................................36
Figure 6-3. CPC-DX with applied electrical power – green LED illuminate. ........37
Figure 6-4. Loading the Settings File to the CPC-II device..................................37
Figure 6-5. Basic parameters verification.............................................................38
Figure 6-6. Basic parameters verification.............................................................39
Figure 6-7. Manual Control Mode Enabled. .........................................................40
Figure 6-8. Isolation valve OPEN / CLOSED lever position.................................41
Figure 6-9. CPC-DX unit with all isolation valves in CLOSED position................42
Figure 6-10. Primary Gain adjustment .................................................................42
Figure 6-11. Performance verification on Performance Trend chart....................43
Figure 6-12. Performance verification on Performance Trend chart....................43
Figure 6-13. Manual Control Mode Disabled........................................................44
Figure 6-14. Pressure offset value verification between CPC-II units..................45
Figure 6-15. PC Service Tool communication disconnection with CPC-II...........46
Figure 6-16. RS-232 cable disconnection from CPC-II communication port. ......46
Figure 6-17. CPC-II cover tightening....................................................................47
Figure 6-18. CPC-II locking clamp tightening.......................................................47

Manual 26824 CPC-II Unit Replacement Procedure
vi Woodward
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.
On-Line Modification,
Reconfiguration or
Start-Up
The configuration and dynamic settings for CPC-II converters must
be precisely matched prior to engaging in concurrent “live” (on-line)
operation or “live” transition between converters on an end
application. Failure to precisely match and tune the configuration of
converters to the proper control range prior to engaging in a “live”
(on-line) replacement could result in turbine overspeed, loss of
control, plant shutdown, property damage and severe bodily injury,
including death.
Proper converter configuration and dynamic settings are unique to
specific end applications. It is the responsibility of the end user to
determine the specific configuration and dynamic settings necessary
for each specific converter application. This CPC-II Unit
Replacement Procedure is a guideline that is dependent upon user-
supplied configuration and dynamic setting data. Because of the
variability of end applications, Woodward makes no warranty,
express or implied, as to the suitability of this procedure for any
given “live” installation.
End users must develop site procedures suitable for specific end
applications, and ensure that personnel are fully trained on such
procedures prior to attempting to replace a converter on a “live”
running turbine. All safety protective systems (overspeed, over
temperature, overpressure, etc.) must be in proper operational
condition prior to the start of an on-line replacement procedure.
Personnel should be equipped with appropriate personal protective
equipment to minimize the potential for injury due to release of hot
hydraulic fluids, exposure to hot surfaces and/or moving parts
located in the area of control of the CPC-II.

Manual 26824 CPC-II Unit Replacement Procedure
Woodward vii
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.
Overspeed /
Overpressure
Never close the drain line when supply pressure is present on the
CPC unit, otherwise the control output pressure can increase
suddenly and cannot be controlled by the input setpoint. This could
cause the turbine to overspeed. The supply pressure isolation valve
and the control pressure isolation valve should always be closed
prior to closing the drain line.
Never disconnect redundancy linkage between CPCs when both
units are powered.

Manual 26824 CPC-II Unit Replacement Procedure
viii Woodward
Only trained personnel are allowed to work on this device during
operation.
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.
It is recommended when performing the removal of a CPC-II
converter from the CPC-DX skid that the isolation valves be secured
with appropriate locks and tags, in accordance with the installation
sites safety procedures.

Manual 26824 CPC-II Unit Replacement Procedure
Woodward ix
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.
Special Conditions for Safe Use
Wiring must be in accordance with North American Class I, Division 1 or 2, or
European Zone 1, Category 2 or Zone 2, Category 3 wiring methods as
applicable, and in accordance with the authority having jurisdiction.
Field wiring must be suitable for at least 85 °C and 10 °C above the maximum
fluid and ambient temperatures.

Manual 26824 CPC-II Unit Replacement Procedure
x Woodward
The CPC-DX must be used in an ambient temperature range from –40 to +85°C
(-40 to + 185⁰F).
The working fluid temperature must be in range +15 to +70°C (+59 to 158⁰F).
For proper operation and safety, ensure the safety ground is properly terminated
to a proper earth ground.
Compliance with the Machinery Directive 2006/42/EC noise measurement and
mitigation requirements is the responsibility of the manufacturer of the machinery
into which this product is incorporated.
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.
Risque d’explosion—Ne pas raccorder ni
débrancher tant que l’installation est sous
tension, sauf en cas l’ambiance est décidément
non dangereuse.
La substitution de composants peut rendre ce
matériel inacceptable pour les emplacements de
Classe I, applications Division 1 ou 2 ou Zone 2.