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 Out-of-date translations are marked with .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