ProAct™ Digital Plus Electric Actuator with Integral Driver

Product Manual 26112
(Revision T)
Original Instructions
ProAct™ Digital Plus Electric Actuator
with Integral Driver
Installation and Operation Manual

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 or updated since this copy was produced. To verify that
you have the latest revision, be sure to check the publications page on the Woodward website:
www.woodward.com/publications
The current revision and distribution restriction of all publications are shown in manual 26311.
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.
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 battery-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.
Revisions—Text changes 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.
Copyright © Woodward 2001
All Rights Reserved
Manual 26112
ProAct Digital Plus
Contents
REGULATORY COMPLIANCE ....................................................................... IV ELECTROSTATIC DISCHARGE AWARENESS ................................................. VI CHAPTER 1. GENERAL INFORMATION ........................................................... 1 Introduction .............................................................................................................1 How to Use This Manual ........................................................................................1 Description ..............................................................................................................1 Controller Overview ................................................................................................2 Mechanical Setup ...................................................................................................4 CHAPTER 2. HARDWARE INSTALLATION ....................................................... 8 Unpacking ...............................................................................................................8 Mounting Location ..................................................................................................8 Actuator Application Guidelines .............................................................................9 Mounting .................................................................................................................9 Actuator Selection and Temperature Monitoring Guidelines..................................9 Fuel Position Stops...............................................................................................12 Linkage .................................................................................................................12 CHAPTER 3. WIRING .................................................................................. 18 Electrical Connections ..........................................................................................18 ProAct Inputs/Outputs ..........................................................................................26 Communication Hardware Descriptions ...............................................................28 CHAPTER 4. SETUP, CALIBRATION, AND ADJUSTMENTS ............................. 30 General Description ..............................................................................................30 Setup ....................................................................................................................30 Calibration ............................................................................................................30 Adjustments ..........................................................................................................30 CHAPTER 5. DESCRIPTION OF OPERATION ................................................. 31 Position Control ....................................................................................................31 Position Demand ..................................................................................................31 Multiple Demands .................................................................................................32 Driver Output and Position Feedback ..................................................................32 Drive Current Limitations ......................................................................................33 Current Limiting Based on Temperature ..............................................................33 Communications ...................................................................................................34 CAN Communications ..........................................................................................34 Service Port (RS-232) Communications ..............................................................35 Service Tool ..........................................................................................................35 User Operating Modes .........................................................................................36 CHAPTER 6. DIAGNOSTICS ........................................................................ 38 General Information ..............................................................................................38 Power-up Diagnostics...........................................................................................39 CHAPTER 7. CAN DETAILS........................................................................ 48 Overview ...............................................................................................................48 CAN Bit Timing .....................................................................................................48 Source Address/Harness Code Strategy .............................................................48 Configuration Strategy ..........................................................................................48 CAN Extensions ...................................................................................................48 Diagnostics from ProAct Actuator ........................................................................51 Diagnostics/Events ...............................................................................................51 Woodward
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Contents
Event Codes .........................................................................................................52 Transmission Rate ................................................................................................53 Arbitration .............................................................................................................54 CHAPTER 8. SERVICE TOOL .......................................................................55 Description ............................................................................................................55 Getting Started......................................................................................................58 Watch Window Numeric Format ...........................................................................61 Using Watch Window ...........................................................................................61 Software Version Identification .............................................................................63 Watch Window Standard and Professional ..........................................................63 CHAPTER 9. PROACT™ PARAMETER SETUP ..............................................64 Configure Mode ....................................................................................................64 Configure Mode Parameters ................................................................................66 Adjusting User Stops and Dynamics ....................................................................71 Adjusting and Testing Actuator Dynamics ............................................................77 Service Mode Parameters ....................................................................................78 Monitoring Application Parameters.......................................................................81 CHAPTER 10. TROUBLESHOOTING .............................................................90 Introduction ...........................................................................................................90 Troubleshooting Procedure ..................................................................................90 General System Troubleshooting Guide ..............................................................91 Mechanical Troubleshooting Guide ......................................................................91 Electrical Troubleshooting Guide..........................................................................92 Performance Troubleshooting Guide....................................................................94 CHAPTER 11. PROACT™ DIGITAL PLUS SPECIFICATIONS ...........................96 Environmental Specifications ...............................................................................96 Hardware Specifications .......................................................................................96 Electrical Specifications ........................................................................................97 I/O Specifications ..................................................................................................97 Software................................................................................................................99 CHAPTER 12. PRODUCT SUPPORT AND SERVICE OPTIONS .......................101 Product Support Options ....................................................................................101 Product Service Options .....................................................................................101 Returning Equipment for Repair .........................................................................102 Replacement Parts .............................................................................................102 Engineering Services ..........................................................................................103 Contacting Woodward’s Support Organization ..................................................103 Technical Assistance ..........................................................................................104 APPENDIX. PROACT™ PROGRAM SUMMARY ............................................105 Configure Mode Settings ....................................................................................105 Service Mode Settings ........................................................................................105 Service Tool Passwords .....................................................................................107 Summary of Alarms and Shutdowns ..................................................................109 REVISION HISTORY ..................................................................................111 DECLARATIONS .......................................................................................112 ii
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Illustrations and Tables
Figure 1-1. ProAct Digital Plus Functional Overview .............................................3 Figure 1-2. Driver Overview....................................................................................4 Figure 2-1. Temperature Monitoring Zone (model III shown)...............................10 Figure 2-2. Base Mount Actuator Selection Guidelines .......................................10 Figure 2-3. Flange Mount Actuator Selection Guidelines.....................................11 Figure 2-4. Fuel Stops ..........................................................................................12 Figure 2-5a. ProAct Digital Plus Actuator Outline Drawing ..................................14 Figure 2-5b. ProAct Digital Plus Actuator Outline Drawing ..................................15 Figure 2-5c. ProAct Digital Plus Actuator Outline Drawing ..................................16 Figure 2-5d. ProAct Digital Plus Actuator Outline Drawing ..................................17 Figure 3-1a. Control Wiring Diagram (blank cover) ..............................................19 Figure 3-1b. Control Wiring Diagram (CAN only) .................................................20 Figure 3-1c. Control Wiring Diagram (Digital Plus) ..............................................21 Figure 3-1d. Control Wiring Diagram (CAN only with External Run Enable) .......22 Figure 3-2. Representative I/O Schematic ...........................................................23 Figure 3-3. Correct Wiring to Power Supply .........................................................25 Figure 3-4. Incorrect Power Supply Wiring...........................................................25 Figure 5-1. Controller Overview ...........................................................................31 Figure 5-2. Primary/Backup Position Demand State Machine .............................32 Figure 5-3. Current Limits .....................................................................................34 Figure 5-4. Operating Modes ...............................................................................35 Figure 5-5. Typical Service Tool Screen ..............................................................37 Figure 6-1. Typical Flash Code ............................................................................41 Figure 7-1. Typical Arbitration Field Example ......................................................54 Figure 8-1. Operating Modes ...............................................................................56 Figure 9-1. Configure Mode .................................................................................65 Figure 9-2. Configure Mode: Mode ......................................................................67 Figure 9-3. Configure Mode: Unit Setup...............................................................69 Figure 9-4. Configure Mode: Demand Setup .......................................................70 Figure 9-5. Min/Max Stops Relative to the Overall Travel ....................................71 Figure 9-6. Electrical Stop Adjustments Relative to the Mechanical Min and Max
Stops ................................................................................................73 Figure 9-7. Service Mode: Adjust User Stops ......................................................73 Figure 9-8. Auto Stroke Mode Flowchart ..............................................................75 Figure 9-9. Manual Stroke Mode Flowchart .........................................................76 Figure 9-10. Service Mode: Hardware Adjustments ............................................78 Figure 9-11. Service Mode: Unit Status ...............................................................81 Figure 9-12. Service Mode: Position Control........................................................83 Figure 9-13. Service Mode: Status Error Alarms .................................................85 Figure 9-14. Service Mode: Status Error Shutdowns ...........................................86 Figure 9-15. Service Mode: Status Error Log (1) .................................................87 Figure 9-16. Service Mode: Status Error Log (2) .................................................88 Figure 9-17. Service Mode: Temperature Histogram ...........................................89 Figure 11-1. Transfer Function ...........................................................................100 Table 1-1. Board Connections ................................................................................5 Table 1-2. Positioning Command Input ..................................................................5 Table 3-1. Driver Power Input ..............................................................................26 Table 3-2. Maximum Distance from 24 V Power Source to ProAct Actuator .......27 Table 3-3. Maximum Distance from 18 V Power Source to ProAct Actuator .......27 Table 3-4. RS-232 Port Pinout .............................................................................29 Table 3-5. ProAct CAN Address ...........................................................................29 Table 9-1. Approximate Inertia Setting for Two Identical Steel Levers ................77 Table 11-1. Transfer Function Parameters ........................................................100 Woodward
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Regulatory Compliance
European Compliance for CE Mark:
EMC Directive:
Declared to 2004/108/EC COUNCIL
DIRECTIVE of 15 December 2004 on the
approximation of the laws of the Member States
relating to electromagnetic compatibility and all
applicable amendments.
Other European Compliance:
Compliance with the following European Directives or standards does not qualify
this product for application of the CE Marking:
Machinery Directive:
Compliant as partly completed machinery with
Directive 2006/42/EC of the European
Parliament and the Council of 17 May 2006 on
machinery.
North American Compliance:
This listing is limited only to those units identified for use in hazardous locations
and bearing the CSA logo. This product is certified as a component for use in
other equipment. The final combination is subject to acceptance by CSA
International or local inspection.
CSA:
CSA Certified for Class I, Division 2, Groups A,
B, C, & D, T4 at 85 °C Ambient for use in
Canada and the United States
Certificate 1167451
This listing is limited only to those units identified for use in ordinary locations and
bearing the CSA logo.
CSA:
CSA Certified for Ordinary Locations at 85 °C
Ambient for use in Canada and the United
States
Certificate 1167451
This listing is applicable to those units identified
for use in ordinary locations and bearing the
CSA logo.
Marine Compliance:
Lloyd’s:
Marine propulsion and auxiliary products in
categories ENV1, ENV2, ENV3, and ENV4 as
defined in LR Type Approval Test Specification
No. 1, 1996.
Type Approval Certificate 01/60006
Peripheral equipment must be suitable for the location in which it is used.
General Installation and Operation Notes and Requirements:
The ProAct Digital Plus is suitable for use in Class I, Division 2, Groups A, B, C,
and D per CSA for Canada and US, Ordinary Locations per CSA for Canada and
US, or non-hazardous locations only, depending on the individual unit labeling.
Specifically marked units are suitable for use in Ordinary Locations per UL for US
and Canada.
For units marked for use in hazardous locations, wiring must be in accordance
with North American Class I, Division 2 wiring methods as applicable, and in
accordance with the authority having jurisdiction. For ordinary locations and
non-hazardous location uses, wiring must be in accordance with the authority
having jurisdiction.
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In order to maintain the NEMA 3R outdoor rating, any wiring connections to the
ProAct must be done in accordance with NEMA 3R standards and practices.
Field wiring must be suitable for at least 85 °C.
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 remove covers or connect/disconnect
electrical connectors unless power has been switched off or the area
is known to be non-hazardous.
Substitution of components may impair suitability for Class I,
Division 2.
RISQUE D’EXPLOSION—Ne pas enlever les couvercles, ni
raccorder / débrancher les prises électriques, sans vous en
assurez auparavant que le système a bien été mis hors
tension; ou que vous vous situez bien dans une zone non
explosive.
La substitution de composants peut rendre ce matériel
inacceptable pour les emplacements de Classe I, Division 2.
Jumpers should not be moved or changed unless power has been
switched off.
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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.
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Chapter 1.
General Information
Introduction
This manual describes the Woodward ProAct™ Digital Plus Actuator for engine
applications. This manual provides installation instructions, describes the control,
and explains the configuration (programming), adjustments (service mode), and
hardware specifications. This manual does not contain instructions for the
operation of the complete engine system. For engine or plant operating
instructions, contact the plant-equipment manufacturer.
This revision of the manual applies to all ProAct Digital Plus models with software
version 2.00 or newer.
How to Use This Manual
The following summarizes how to install a ProAct actuator into a new or existing
system.

Unbox and inspect the hardware for any visible damage caused during
shipping.

Mount the actuator and linkages following the procedures and
recommendations in Chapter 2.

Wire the actuator—see Chapter 3.

Refer to Chapter 4 for guidelines on calibration and setup.
The actuator must be properly set up using the Service Tool prior to
starting the engine.
The inertia setting must be properly adjusted using the Service Tool
prior to engine operation. An improper inertia setting will result in
undesirable performance.
The Service Tool is not included, but can be download from the
Woodward Internet website (www.woodward.com) or by ordering the
Watch Window Standard CD-ROM (1796-065).
Description
The ProAct Digital Plus is a family of electric actuators with integral drivers
intended to be mounted on-engine to control varying functions including (but not
limited to): fuel rack positioning, timing control, and throttle valve and wastegate
positioning. The device is effectively a positioner which will accept a desired
position signal from another device in the system, such as a speed control, and
drive to that position. Each unit includes a digital driver capable of controlling the
actuator, communicating with the outside control system, and containing onboard software and intelligence to realize monitoring and customizing functions.
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Manual 26112
The ProAct Digital Plus actuator can be commanded to a position via (4 to 20)
mA, (0 to 200) mA, PWM, or CAN interfaces. In addition, given an on board
position feedback device, the actual position is available to the system through a
position output signal.
Each member of the ProAct Digital Plus family has a different bi-directional
torque output capability as described in Chapter 11 (Specifications). In addition,
each actuator has a nominal rotation of 75° at the output shaft. It can be mounted
in either a base mount or flange mount configuration, with the exception of the
ProAct Digital Plus Model IV which can only be base mounted. The units are
designed to operate in an on-engine environment and can therefore withstand
high levels of vibration and temperature extremes. The details of these
environmental limits can be found in the Environmental Specifications section in
Chapter 11.
As described in the Regulatory Compliance section, the ProAct Digital Plus
family of actuators meets CSA requirements for Class I, Division 2 or Ordinary
Locations for North America, and CE Marking requirements.
Controller Overview
The position controller software is executed on a 20 MHz 68376 32-bit
microcontroller onboard the ProAct Driver. Internal current and position sensors
provide feedback for closed-loop position control. The driver interfaces with an
external speed control via a position demand. The position demand can be an
analog signal (0 mA to 20 mA or 0 mA to 200 mA), a PWM signal, or optional
CAN. The driver can also be configured to accept redundant demand signals.
The ProAct control monitors all available signals, internal and external, and
annunciates any detected faults through the discrete output. An analog output
provides actual position indication, and a discrete input is available to remotely
shut down the actuator.
Features of the driver include model-based position and current control loops,
on-line and off-line diagnostics, current limiting based on electronics temperature,
CAN communications, and service port communications.
The ProAct control is field programmable, which allows a single design to be
used in many different applications. The driver must be configured and field
calibrated to the specific engine using the Service Tool software. The Service
Tool software is loaded on a PC and communicates serially to the driver via
RS-232 using Woodward’s DDE Servlink protocol. Refer to Chapter 8 (Service
Tool) for installation instructions. Figure 1-2 provides an overview of the ProAct
Digital Plus driver I/O (inputs/outputs).
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Figure 1-1. ProAct Digital Plus Functional Overview
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Position
Feedback
Output
SPI
Port
Filtered
Power
(daughter board)
CANbus Serial
Communications
(optional)
Discrete Input
and Output
Local User
Setup Only
Position
Feedback
Future Expansion
End User I/O
Command
Inputs
Actuator
Drive
Internal Wiring
Power
Input
RS-232 Serial
Communications
ProAct Driver
Figure 1-2. Driver Overview
Mechanical Setup
Mounting
The ProAct Digital Plus platform is base mounted to tapped holes on the bottom
of the actuator containing through-holes (see Figure 2-5). In addition, the models
I, II, and III have the capability of being flange mounted. The unit can be mounted
in any orientation. All exterior and mounting dimensions and exterior fasteners
are metric. See Chapter 2 (Installation) for details on mounting and installation.
Output Shaft
The ProAct Digital Plus family output shafts are standard US-customary sizes
with toothed serrations. A rotation scale and indicator are available as an optional
kit for visible detection of travel (for reference only).
Rotation
All ProAct Digital Plus actuators have 73–77 of available travel. The max fuel
direction of this travel is software configurable in the clockwise or
counterclockwise direction through the Service Tool.
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Mechanical Stops
Internal mechanical actuator stops will only survive a maximum kinetic energy of
0.011 J (0.097 in-lb). If the actuator internal stops are used, the load inertia should
not exceed 3.76E-3 in-lb-s² (4.25E-4 kgm²). See Chapter 2 (Linkage) for details on
actuator inertia and internal stops. In service, electrical and engine stops should be
set inside the actuator stops. Electrical stops are set via the Service Tool.
Electrical Connections
There are three interfaces on the circuit board. Refer to Chapter 3 for details on
ProAct actuator wiring.
Interface
Service Port
Power Taps
Terminal Strip
Type
9-pin sub-D male
Insulated Spade or
Ring Lug
Terminal Block
Use
Located beneath the customer entry plate.
For 24 V (dc) connection.
All other functions.
Table 1-1. Board Connections
An optional M37 blanking plug is available to make connections to
the 9-pin sub-D male service port. This port should be used only for
configuration and setup. Thread lock should be used to secure the
blanking plug.
Position Command Input
There are four possible position command signals. See the table below for an
overview of the signals and corresponding input signal to actuator position. All
adjustments are done via the Service Tool software. All circuits are protected
against short circuit to battery negative. These short circuits will not cause
damage to the control.
Input Signal
Nominal Range
Adjustment Range
PWM:
20 % to 80 % Duty
Cycle
10 % to 90 % Duty
Cycle
(20 to 180) mA
(0.0 to 200) mA
(4 to 20) mA
(0.0 to 25) mA
n/a
n/a
(7 to 32) V
(100 to 3000) kHz
Analog:
(0 to 200) mA
Analog:
(4 to 20) mA
CAN Command
Actuator Output for
Input Range
0 % to 100 %
Actuator Position
0 % to 100 %
Actuator Position
0 % to 100 %
Actuator Position
0 % to 100 %
Actuator Position
Table 1-2. Positioning Command Input
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Inputs/ Outputs (I/O)




The following Inputs/Outputs (I/O) are available in the ProAct Digital Plus:
power input

1 discrete output
1 analog input

1 analog output
1 PWM input

1 RS-232 communications port
3 discrete inputs

1 CAN (Controller Area Network) port (optional)
Refer to the control wiring diagram (Figure 3-1) for wiring overview. Refer to
Chapter 3 for wiring details.
Power Input
The input power has an operational range of (18 to 32) V (dc), nominal 24 V (dc).
Input power out of range diagnostics are provided.
Analog Input for Position Demand
The analog input is configurable for either (20 to 180) mA (200 mA range) or
(4 to 20) mA (25 mA range). The range is selected using the jumper on the
terminal board—JPR1 for 200 mA range and JPR2 for 20 mA range. Range and
failure diagnostics are provided based on software configuration and settings.
PWM Input for Position Demand
The PWM input accepts a (100 to 3000) Hz input signal of (7 to 32) V peak voltage
(referenced to unit battery ground). The PWM input duty cycle minimum and
maximum are field adjustable to match the controller sending the demand. Range
and failure diagnostics are provided based on software configuration and settings.
Discrete Input—Low Power Standby Mode
(option may not be available on current-input models)
When opened, the driver goes into a Low Power Standby Mode. The Low Power
Standby Mode causes the current driver and the analog output to be
de-activated, to minimize the power consumption of the driver. This input is
connected to ground, preferably Discrete Common, for a logic ‘true’.
The Status Output can also be configured to de-activate when the unit is put into
Low Power Standby Mode. See Chapter 9 for Configure Mode Parameters to set
Discrete Out Includes Runenable [Run/Enable].
If using firmware version 2.20 Woodward part number 5418-2590, it is
possible to configure this input for Run Enable – Closed to Run =
False. With this configuration, the contacts are open to run, and
closed to enter Low Power Standby Mode.
This input must be closed to operate the unit. When open, the unit is
forced into a non-operational shutdown state.
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Alternatively, if it is desired to completely reduce the power consumption of the
driver to zero, power can be completely disengaged from the unit with a
customer installed switch on the input power. We recommend that the Low
Power Standby Mode be activated before opening the power lines to minimize
the unit’s current draw and to store internal parameters.
Discrete Inputs—CAN Address Identification
The CAN Hi and Lo discrete inputs provide an address based on input
open/closed status on initialization. Four CAN address combinations (1–4) are
available. For example, both contacts open means that the unit address is ‘1’,
and both closed means unit ’4’. These inputs are connected to ground, preferably
Discrete Common, for a logic ‘true’.
Discrete Output—Driver Status Indication
The discrete output is normally ON (24 V provided to the load), and turns
off/opens to indicate any detected fault (alarm or shutdown) condition within the
ProAct Digital Plus. Fault conditions are non-latching, which means a reset
command is not required when the condition clears. The Service Tool program
can be used to interrogate the cause of the alarm or shutdown as well as provide
a historical log of events (see Event Log). The optional CAN communications can
also be used to determine alarm and shutdown causes.
The ProAct Digital Plus will continue to operate with an alarm condition (for
example, failure of the primary demand signal). However, the unit will cease to
operate on a shutdown condition (for example, failure of both primary and backup
demand signals).
4 mA to 20 mA Analog Output for Indication of Actual Position
to an External Device
An analog output of 4 mA and 20 mA corresponds to 0 % and 100 % actuator
travel, respectively. Offset and gain adjustments are provided.
RS-232 Communications Port
An RS-232 communications service port is provided with a 9-pin sub-D male
connector for connection to a PC service tool. This connection is a typical threewire null modem RS-232 communication which is limited to 15 m (50 feet; RS-232
limitation). The port supports Woodward Servlink (DDE) protocol and has fixed
communications settings of 19.2 K baud rate, 8 data bits, no parity, and 1 stop bit.
CAN Communications Port (optional)
The driver has CAN communications, version 2.0B, with 29-bit identifiers. The
protocol complies with SAE J1939, but uses proprietary group extensions. The CAN
port supports positioning (position demand from CAN) of the driver. It also supports
ProAct Digital Plus monitoring of all shutdown and alarm conditions as well as some
system variables. The address is determined by the CAN address discrete inputs.
The data rate may be chosen from 250 kbps, 500 kbps, and 1 Mbps.
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Chapter 2.
Hardware Installation
This chapter provides instructions on how to mount and connect the ProAct™
Digital Plus actuator into a system. Hardware dimensions are provided for
mounting the ProAct package to a specific application.
External fire protection is not provided in the scope of this product. It
is the responsibility of the user to satisfy any applicable
requirements for their system.
Due to typical noise levels in turbine environments, hearing
protection should be worn when working on or around the ProAct
Actuator.
The surface of this product can become hot enough or cold enough
to be a hazard. Use protective gear for product handling in these
circumstances. Temperature ratings are included in the specification
section of this manual.
Unpacking
Be careful when unpacking the actuator. Check the unit for signs of damage,
such as bent or dented panels, scratches, and loose or broken parts. Notify the
carrier and Woodward if damage is found.
Mounting Location
The ProAct Digital Plus actuator is designed to operate within a temperature range
of –40 to +85 °C (–40 to +185 °F). Mount the driver close enough to the battery to
meet the wire-length requirements (see wiring instructions in Chapter 3).
The ProAct actuator is designed for installation on the engine. The ProAct
actuator will generate heat, especially when stalled or during other conditions
requiring maximum torque output. 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 highcarbon steel or stainless steel.
A minimum gap of 0.5 mm must be maintained between the support
bracket and electronics enclosure (see Figure 2-1). This is necessary
because the enclosure is supported on vibration isolators to filter out
high-frequency vibrations from reaching the electronics. If the
enclosure contacts the bracket, the isolation is defeated and may
reduce the electronics operating life.
If spacers are used to achieve the necessary gap, Woodward
recommends maximizing the surface contact area of the spacers to
maximize heat transfer between the ProAct and mounting bracket.
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Actuator Application Guidelines
The following sections include environmental guidelines for applying the ProAct
Digital Plus. By adhering to the limitations and recommendations set forth in
these sections, the customer will realize the full functionality of the actuator and
improve its overall reliability.
Mounting
Models I through IV actuators may be installed on a bracket in either base or
flange mount configuration with the exception of the model IV. The mass of the
model IV requires that it be mounted only in the base mount configuration. The
base mount configuration requires the use of four M8x1.25 screws with a
minimum engagement of 16 mm. The flange mount configuration requires the
use of four M8 screws through the flange. Whether base mounting or flange
mounting the actuator, torque the four M8 screws to 22.6 Nm (200 lb-in). The
actuator may be mounted in any attitude.
The ProAct Digital Plus weighs approximately:
Model I
Model III
11 kg (25 lb)
15 kg (32 lb)
Model II 11 kg (25 lb)
Model IV 24 kg (52 lb)
The bracket and attaching hardware must be designed to hold the weight and to
withstand the vibration associated with engine mounting. Additionally, the bracket
must be designed to provide a heat sink (heat transfer) from the actuator to the
engine block as described in the following section.
As shown in Chapter 11, ProAct Digital Plus Specifications, the ProAct actuators
have been designed for and verified to a given accelerated life vibration test level
at the mounting surface of the actuator. The user should be aware that in any
application, bracket design can significantly change the vibration levels at the
actuator. Therefore, every effort should be made to make the bracket as stiff as
possible so that engine vibrations are not amplified, creating an even more
severe environment at the actuator. Additionally, when possible, orienting the
actuator shaft parallel to the crankshaft of the engine will often reduce the
vibration load on the actuator's rotor system in reciprocating engine applications.
Actuator Selection and Temperature Monitoring
Guidelines
The thermal design of the ProAct Digital Plus is based on the cooling of critical
electrical components coupled to the aluminum frame of the actuator. In this
manner, by maintaining a certain temperature at a specified location on the
actuator frame, the temperature of the electronics will be maintained within
acceptable limits. Therefore, when applying the ProAct Digital Plus actuator, the
area shown in the following diagram (Figure 2-1) must not exceed 90 °C
regardless of the surrounding thermal conditions. If the temperature of this zone
does exceed 90 °C, thermal based actuator output limiting may begin depending
on user-configurable options. The limiting area shown in Figure 2-1 is referred to
as the temperature monitoring zone.
CSA hazardous or CSA and UL ordinary location certification of the
ProAct Digital Plus is not applicable if the ambient temperature
exceeds 85 °C.
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ELECTRONICS
PACKAGE
TEMPERATURE
MONITORING ZONE
(0.5 mm)
MOUNTING GAP
Figure 2-1. Temperature Monitoring Zone (model III shown)
Figure 2-2. Base Mount Actuator Selection Guidelines
CSA hazardous and CSA and UL ordinary location certification of the
ProAct Digital Plus is not applicable if the ambient temperature
exceeds 85 °C.
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Figure 2-3. Flange Mount Actuator Selection Guidelines
In order to determine whether a customer-specific application will meet this
temperature limitation, the following charts are included (Figures 2-2 and 2-3).
For each mounting condition the chart gives a general guideline for the
surrounding environment. In each case, if the measured temperatures of the
environment fall under the limiting curve, the temperature monitoring zone should
be under the acceptable 90 °C limit. Note that these curves are guidelines based
on actuator testing and modeling. After installation, the true thermal condition
must be determined by testing the temperature monitoring zone. Each chart
contains three curves representing different actuator output levels. These output
levels, and the loading they represent on the actuator, affect the temperature
limits. Regardless of the measured temperature in the temperature monitoring
zone, CSA hazardous and CSA and UL ordinary locations listings are not
applicable if the surrounding air ambient temperature exceeds 85 °C.
Both charts assume a smooth mounting surface with good heat transfer
characteristics. In addition, the ambient temperatures shown are based on the air
velocities present in a test oven. Therefore, if significant air flow is present, these
temperatures can potentially be increased. Similarly, if the surrounding air is
highly stagnant, these temperatures my need to be decreased. The specific
environment must be verified by checking the temperature monitoring zone given
that these curves are only guidelines and many factors can effect the actual
thermal conditions on an engine.
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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 2-4).
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 actuator
internal stops will allow up to 1.5 degrees of additional rotation in both directions
during impact (see Figure 2-4).
The engine must always shut down when the actuator is at the minimum stop.
Figure 2-4. Fuel Stops
Linkage
Proper design and installation of the linkage from the actuator to the engine is
necessary for the unit to provide the best control possible.
Certain applications with low inertia may be unstable with high impulse loads and
may require additional system inertia. See troubleshooting guidelines or contact
Woodward for more information.
Ensure 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 backlash. Lubricate
or replace worn linkage or fuel control parts as required.
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The actuator contains no internal return spring, therefore an external positive
shutdown is necessary in the event of a loss of power to the actuator.
The actuator’s maximum slew rate can place stress on the fuel
system stops and on the linkage between the actuator and the fuel
system. The maximum actuator speed is 1000 degrees per second in
both increase and decrease fuel directions.
The Mass Moment of Inertia (MMOI) for the ProAct Digital Plus actuators are:
Model I, II 4.9E-3 lb-in-s² (5.5E-4 kgm²)
Model III 5.6E-3 lb-in-s² (6.4E-4 kgm²)
Model IV 7.2E-3 lb-in-s² (8.2E-4 kgm²)
The fuel system stops must be adequate to absorb the actuator MMOI in addition
to the linkage inertia without damage.
ProAct actuator internal stops are designed to absorb 0.011 J (0.097 in-lb) of
kinetic energy with 1.5 degrees of over travel. If the actuator stops are used, the
load inertia must not exceed 3.76E-3 in-lb-s² (4.25E-4 kgm²), and the linkage
must be designed to allow the 1.5 degrees of over travel on each end.
Use of good rod-end connectors with as little free play as possible is essential.
Select rod ends which will remain tight and 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 while the engine is running.
Typically, in a linkage system, there may be links and levers which are supported
by customer-supplied bearings. Additionally, there will typically be a section of
the linkage where the mass is supported fully by the actuator output shaft. Please
note when designing these systems that each ProAct Digital Plus actuator is
designed to accept 1.2 kg (2.6 lb) of additional mass at a maximum vibration
level of 10 Gs. Exceeding this mass or vibration level may damage the actuator's
rotor system and shorten the life of the actuator.
Actuator levers are available from Woodward which allow adjustment of the rod
end locations with respect to the center of the actuator shaft. The lever used
must have a 0.625-36 serration.
Adjust the location of the rod end on the lever to achieve the desired actuator
rotation between minimum and maximum positions. The linkage should be set to
use as much of the 75 degrees as possible (at least 60 degrees minimum). To
increase the amount of actuator rotation, move the rod end closer to the actuator
shaft or farther away from the shaft controlling the fuel flow. To decrease the
amount of actuator rotation, move the rod end farther from the actuator shaft or
closer to the shaft controlling the fuel flow.
The actuator must be stroked using the Service Tool procedure any
time the valve stops or linkage is adjusted.
Follow the procedure in Chapter 9 on Adjusting User Stops and
Dynamics.
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Figure 2-5a. ProAct Digital Plus Actuator Outline Drawing
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Figure 2-5b. ProAct Digital Plus Actuator Outline Drawing
(Pilot Adaptor Version)
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Figure 2-5c. ProAct Digital Plus Actuator Outline Drawing
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Figure 2-5d. ProAct Digital Plus Actuator Outline Drawing
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Chapter 3.
Wiring
This chapter provides instructions on how to connect the ProAct™ actuator into a
system. Ratings and jumper configurations are given to allow wiring and
configuration of the ProAct package to a specific application.
Electrical ratings, wiring requirements, and options are provided to allow full
installation the ProAct actuator into a new or existing application.
Jumpers should not be moved or changed unless power has been
switched off.
Electrical Connections
If you are replacing an earlier ProAct series actuator with the ProAct
Digital Plus model, be sure to remove the original driver, since the
ProAct Digital Plus actuator has an integrated driver.
Due to the hazardous location listings associated with this product,
proper wire type and wiring practices are critical to operation.
Do not connect any cable grounds to “instrument ground”, “control
ground”, or any non-earth ground system. Make all required
electrical connections based on the wiring diagrams (Figure 3-1).
Refer to the control wiring diagram (Figure 3-1), the representative I/O interface
schematic (Figure 3-2), and the Specification section of the manual for the
hardware I/O specifications.
All inputs and outputs to the ProAct actuator are accessed beneath the end cover
which is fastened with 6 M4x10 mm, screws (see the outline drawing, Figure 21).
An optional M37 blanking plug is available to make connections to
the 9-pin sub-D male service port. This port should be used only for
configuration and setup. Thread lock should be used to secure the
blanking plug.
Input power is connected to size M4 screws. The wires must be terminated with
insulated spade or ring lugs. Wires for the fixed mounted power terminals should
be stripped 5–6 mm (0.2 inch).
The I/O terminal blocks are screwless cage clamp style blocks. The spring clamp
can be actuated by pressing down on the thumb levers integral to the block. The
terminal blocks accept wires from 0.20 – 3.3 mm² (24 -12 AWG) wire. Two 0.82
mm² (18 AWG) or three 0.5 mm² (20 AWG) wires can easily be installed in each
terminal. Wire for the I/O terminals should be stripped 8–9 mm (0.3 inch).
To ensure electromagnetic compliance, cables attached permanently
to the unit must be limited to 30 meters.
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Figure 3-1a. Control Wiring Diagram (blank cover)
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Figure 3-1b. Control Wiring Diagram (CAN only)
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Figure 3-1c. Control Wiring Diagram (Digital Plus)
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Figure 3-1d. Control Wiring Diagram (CAN only with External Run Enable)
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Figure 3-2. Representative I/O Schematic
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Cable Shield Termination
The ProAct control is designed for operation without shielded cables. When
shielded cables are provided, terminate the shield to the optional termination
point shown in Figure 2-5d.
Hardware Jumpers
The analog input has a range jumper to select either a 20 mA range (JPR2) or a
200 mA range (JPR1). Refer to Figure 3-1 for jumper locations. Jumpers must
only be moved with input power removed from the ProAct control.
The power must be removed from the ProAct Driver in order to move
any jumpers.
Grounding and Ground Connections
The multiple ground connections are provided for variations in local wiring codes.
An internal power ground connection (see Figure 3-1a) and an external ground
connection (other than the mounting) are both provided. Refer to the external PE
Ground connection identified in Figure 2-5.
Customers must use the grounding point that meets local authority
approval requirements.
Power Source
Power source output must be low impedance (for example, directly from
batteries). Run an insulated wire directly from the positive (+) battery terminal
and negative (–) battery terminal to the correct connection on the driver (see
Figure 3-3). Run a second insulated wire directly from the negative (–) terminal of
the battery to the driver. Neither of these connections needs to be shielded.
Run the power leads directly from the power source to the control. DO NOT
POWER OTHER DEVICES WITH LEADS COMMON TO THE CONTROL (see
Figures 3-3 and 3-4). If the power source is a battery, be sure the system
includes an alternator or other battery-charging device.
When the engine is shut down, the driver powers the actuator into 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 remove power from the driver for normal shutdown
procedures. All actuator position commands should come from the
control unit, through the driver, to the actuator. Engine overspeed is
possible if power is removed from the driver while the engine is
running.
To prevent possible damage to the control, or poor control
performance resulting from ground loop problems, follow these
instructions.
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Figure 3-3. Correct Wiring to Power Supply
Figure 3-4. Incorrect Power Supply Wiring
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ProAct Inputs/Outputs
Actuator Input Power
The following table summarizes the driver power input requirements. The input
voltage operational range is (18 to 32) V (dc), 24 V (dc) nominal. The power input
provides protection against reverse voltage connection. Refer to Tables 3-1 and
3-2 for maximum cable lengths and wire sizes. Size M4 screws are provided for
power connection requiring either insulated spade- or ring-lug connectors for
termination.
ProAct
Digital Plus
Model
I
II
III
IV
Transient
Power–max
(Watts)
67
251
282
371
Continuous
Power–max
(Watts)
19
65
73
101
Table 3-1. Driver Power Input
Input Power Fusing
The input power must be fused. Failure to fuse the ProAct could,
under exceptional circumstances, lead to personal injury, damage to
the control valve, and/or explosion.
Recommended fuse ratings are listed below.
Model I: 5 Amp Fast Acting Fuse
Model II: 15 Amp Fast Acting Fuse
Model III: 20 Amp Fast Acting Fuse
Model IV: 25 Amp Fast Acting Fuse
All fuses should have a voltage rating of at least 100 V and the I2t (current2 *
time) rating should be at least 2. A typical fast acting fuse will meet these ratings.
The controller can produce transients on the power supply lines
which may interfere with certain regulated power supplies. If this is
the case, the interference may be reduced or eliminated by
connecting a 100 V, 1000 µF or larger capacitor across the power
supply lines. Correct polarity must be observed when connecting the
capacitor.
Input Power Wire Length Considerations
Input power wire lengths should be as short as possible. Maximum wire lengths
are shown in Tables 3-1 and 3-2.
If the recommended cable distances between battery and actuator
are exceeded, torque output will be reduced.
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Recommended maximum wire length from power source to ProAct actuator
based on a 24 V power source.
Input
Power
16 AWG
14 AWG
12 AWG
10 AWG
8 AWG
Max Wire
Length (ProAct
Model I)
51 m / 167 ft
81 m / 266 ft
128 m / 420 ft
202 m / 663 ft
320 m / 1050 ft
Max Wire
Length (ProAct
Model II)
13 m / 43 ft
21 m / 69 ft
34 m / 112 ft
54 m / 177 ft
84 m / 276 ft
Max Wire
Length (ProAct
Model III)
14 m / 46 ft
23 m / 75 ft
37 m / 121 ft
59 m / 194 ft
94 m / 308 ft
Max Wire
Length (ProAct
Model IV)
6 m / 20 ft
9 m / 30 ft
15 m / 49 ft
24 m / 79 ft
37 m / 121 ft
1.5 mm²
2.5 mm²
4 mm²
6 mm²
10 mm²
59 m / 194 ft
99 m / 325 ft
158 m / 518 ft
236 m / 774 ft
393 m / 1289 ft
15 m / 49 ft
26 m / 85 ft
42 m / 138 ft
63 m / 207 ft
103 m / 338 ft
16 m / 52 ft
28 m / 92 ft
46 m / 151 ft
69 m / 226 ft
116 m / 381 ft
7 m / 23 ft
11 m / 36 ft
19 m / 62 ft
28 m / 92 ft
45 m / 148 ft
Wire Size
Table 3-2. Maximum Distance from 24 V Power Source to ProAct Actuator
Recommended maximum wire length from power source to ProAct actuator
based on an 18 V power source.
Max Wire Length
(ProAct Model II)
Max Wire Length
(ProAct Model IV)
Input
Power
Wire Size
Max Wire
Length (ProAct
Model I)
Limited torque
output*
Max Wire
Length (ProAct
Model III)
Limited torque
output*
16 AWG
14 AWG
12 AWG
10 AWG
8 AWG
12 m / 39 ft
54 m / 177 ft
86 m / 282 ft
137 m / 449 ft
217 m / 712 ft
8 m / 26 ft
13 m / 43 ft
21 m / 69 ft
33 m / 108 ft
52 m / 171 ft
5 m / 16 ft
8 m / 26 ft
13 m / 43 ft
21 m / 69 ft
33 m / 108 ft
4 m / 13 ft
6 m / 20 ft
10 m / 33 ft
16 m / 52 ft
26 m / 85 ft
1.5 mm²
2.5 mm²
4 mm²
6 mm²
10 mm²
14 m / 46 ft
66 m / 217 ft
106 m / 348 ft
160 m / 525 ft
267 m / 876 ft
9 m / 30 ft
16 m / 52 ft
25 m / 82 ft
39 m / 128 ft
64 m / 210 ft
6 m / 20 ft
10 m / 33 ft
16 m / 52 ft
25 m / 82 ft
41 m / 135 ft
5 m / 16 ft
7 m / 23 ft
12 m / 39 ft
19 m / 62 ft
32 m / 105 ft
* Note—Rated transient torque is not achievable with an 18 V power source on the
Models II and IV. Listed maximum lengths will provide 75 % of rated transient torque.
Table 3-3. Maximum Distance from 18 V Power Source to ProAct Actuator
Analog Position Command Signal
The analog input will accept a jumper configurable (0 to 25) mA or (0 to 200) mA
input signal with a nominally configured operational range of (4 to 20) mA and
(20 to 180) mA, respectively. The position command input will be capable of
providing a common mode input voltage range (unit battery ground referenced)
of (0 to 32) V for all analog type inputs. The minimum wire size is 0.5 mm² or
20 AWG.
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PWM Position Command Signal
The PWM input will accept a (100 to 3000) Hz PWM input signal of (7 to 32) V
peak voltage (referenced to unit battery ground). The position command input will
be capable of providing a common mode input voltage range (unit battery ground
referenced) of (0 to 4) V for all PWM type inputs. The PWM circuit will accept a
sourcing driver input. The driving circuit must be capable of providing 10 mA of
sourcing current at all battery voltages. The minimum wire size is 0.5 mm² or
20 AWG.
Position Feedback Output
The actuator position signal will be output from the driver as a (4 to 20) mA signal
corresponding to 0 % to 100 % actuator travel. The minimum wire size is
0.5 mm² or 20 AWG.
Run Enable Discrete Input
This discrete input is closed to run and opened for Low Power Standby Mode.
The Low Power Standby Mode provides minimal power consumption of the
device. When the discrete input is opened, power is removed from the actuator
coil, the processor stays active, and the unit consumes less than 200 mA of
current. All communications (CAN and RS-232) remain active while in this mode.
When the input is closed and all shutdown conditions are cleared, the actuator
will position its output to the demanded setting.
If using firmware version 2.20 Woodward part number 5418-2590, it is
possible to configure this input for Run Enable – Closed to Run =
False. With this configuration, the contacts are open to run, and
closed to enter Low Power Standby Mode.
This input must be in Run mode for control the actuator.
Discrete Output
A discrete output is provided to serve as a status indicator. If the driver fails or
shuts down, the discrete output will open. In addition, the discrete output can
optionally open upon any alarm condition. The circuit drives a 48  load at
500 mA at 24 V input.
Communication Hardware Descriptions
Service Port
An RS-232 service port is provided with a 9-pin sub-D male connector beneath
the customer entry plate. Functions available through this port include tuning and
configuration of the driver and actuator. Detailed driver status information is also
available.
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Any RS-232 wiring must meet the requirements in the EIA RS-232 Standard
document. The RS-232 standard states that the maximum length of the RS-232
cable between the driver and the PC must be 50 feet (15 meters) with a total
capacitance less than 2500 pF. The RS-232 data rate is fixed at 19.2 kbps. The
communication port is non-isolated and susceptible to both EMI noise and
ground loops related to PC connections and typical industrial environments.
The service port is not isolated and is not intended to function while
the engine is in normal operation. The service port is provided for
configuration and setup only.
Connector
DB9M
Signal Mnemonic
Shielded DB9 male connector
2
3
5
Shield
ProAct Rx
ProAct Tx
Signal Common
Chassis GND—capacitively coupled
Table 3-4. RS-232 Port Pinout
CAN Communications
The CAN wiring must meet the requirements in the ISO 11898 specification. The
data rate is software configurable between 250 Kbits/sec, 500 Kbits/sec, and
1Mbits/sec. Maximum cable length specifications based on the data rate can be
found in Chapter 11 (Specifications).
Up to four ProAct controls can be on the same CAN bus, however, each must
have a different device address. The CAN device address is determined by the
CAN ID HI and LO discrete inputs upon power-up of the unit (see Table 3-5).
The CAN address discrete inputs must be wired prior to power-up to
be registered.
ProAct Address
CAN ID HI
CAN ID LO
1
Open/High
Open/High
2
Open/High
Closed/Low
3
Closed/Low
Open/High
4
Closed/Low
Closed/Low
Table 3-5. ProAct CAN Address
A built-in 125  termination resistor is provided. Installing a jumper across
terminals 14 and 15 puts the termination resistor across the CAN Hi and Lo
terminals—see Figure 3-2. A termination resistor should be installed on the last
unit of the CAN bus. The termination resistor will help prevent disturbances
and/or reflections of CAN signals.
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Chapter 4.
Setup, Calibration, and Adjustments
General Description
Setup, calibration, and adjustments are all provided through software. To use
these functions, the Service Tool must be installed. Refer to Chapter 8 (Service
Tool) for instructions on installation and operation of the Service Tool.
Setup
The basic setup consists of actuator configuration, actuator stroking, and
dynamics (inertial setting) adjustment. Configuration is not required on most
OEM-supplied units. Configuration is performed using the Service Tool—details
are provided in Chapter 9 (Software Setup). Over 20 Configuration parameters
are available—the Appendix provides a Program Summary worksheet which
gives an overview of these Configure Mode settings.
Actuator stroking is required to ensure that 0 % to 100 % actuator travel provides
an equivalent valve position.
The setup, configuration, stroking, and dynamics adjustment must be performed
when the engine is shut down. These actions all require a password.
The actuator must be stroked using the Service Tool procedure any
time the valve or linkage is adjusted.
Actuator dynamics must be set using the Service Tool Inertia Setting
parameter prior to engine operation.
The Service Tool is not included, but can be download from the
Woodward Internet website (www.woodward.com) or by ordering the
Watch Window Standard CD-ROM (1796-065).
Calibration
The ProAct™ digital control requires no field calibration, the analog signals are
factory calibrated. Adjustments are available in the Service Mode to account for
field variations.
Adjustments
Adjustments are provided to optionally fine-tune an application. Over 20
adjustable parameters are available. Adjustments are available through the
Service Tool—details are provided in Chapter 9 (Software Setup). The Appendix
provides a Program Summary worksheet which gives an overview of these
Service Mode Settings available.
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Chapter 5.
Description of Operation
Position Control
The ProAct™ Digital Plus provides closed-loop position control based on an
internal position sensor and the desired position demand signal. Software modelbased position and current controllers are utilized to position the output. Position
control is provided using a customer's position demand and an internal driver
output while using an internal position feedback sensor. The driver provides a
(4 to 20) mA analog output for indication of actual position. A discrete output is
also available to provide a status indication of the driver itself. Field calibration is
available through the Service Tool PC program to match the stroke of the driver
to that of the field rigging (see User Calibration).
Figure 5-1. Controller Overview
Position Demand
The position demand can be either a single or redundant input; if redundant, the
driver provides primary/backup logic to manage the redundancy internally. The
position demand can be provided by any one of three configurable signal
sources: analog, PWM, or optional CAN. The position demand input signals are
internally scalable to match the demand of the signal’s source. Failure of any
configured position demand signal will issue an alarm (see Alarms section). If all
configured signals are faulty, the ProAct Digital Plus is put into the configured
shutdown state and remains shut down until a valid signal is received. At least
one position demand input must be configured for use for the ProAct actuator to
operate. Software adjustments are available for min and max position demands.
Since they use the same input circuitry, it is not possible to use the (4 to 20) mA
and (0 to 200) mA Analog Input simultaneously in a redundant system.
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Multiple Demands
If redundant position demand signals are configured, one input is the primary
signal and the other is the backup signal. The primary signal and the backup
signal must be different signals and must be selected from the configurable
sources. The configured inputs are monitored, and any faulty signals are
annunciated. Primary and backup demand sources are configured from the
available input signals. As long as the primary signal is okay, it is the position
demand used by the driver. If the primary signal fails, the backup signal is used.
If both primary and backup signals fail, the unit will shut down.
If the backup signal is not tracking the primary signal (tunable magnitude and
duration), an alarm is issued. If the primary demand signal fails, the backup
signal is used even if the signal had a tracking error. If a failed primary demand
signal is restored and tracking within programmed tolerances, control is
transferred from the backup demand to the primary demand input. If a failed
primary demand signal is restored but not tracking within programmed
tolerances, position control remains in the backup demand mode.
Power up
S0
Primary Demand OK
S1
Shut Down
State
Primary
Demand
Control
Primary Demand Failed
(Primary OK for > 10 sec && Not Tracking Error)
OR (Primary OK && Backup Failed)
Backup Demand Failed &&
Primary Demand Failed
S2
Backup Demand OK && Primary Demand Failed
Backup
Demand
Control
Primary / Backup Position Demand State Machine
Figure 5-2. Primary/Backup Position Demand State Machine
Driver Output and Position Feedback
If the internal position or current sensor is out of range, the actuator is put into
the configured shutdown state (see diagnostics). Upon power-up, the unit will
stay disabled until the problem is rectified and a position command signal has
been received in the proper range.
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Drive Current Limitations
The current to the coil is limited to prevent damage. A transient and a steady
state limit are used. The transient current limitation is active during a transition in
position output. After a short delay (about 3 seconds), the steady state limit is
activated if desired position is not reached. The transient and steady state limits
are not adjustable, but are based on the actuator type configured. The nominal
transient and steady current limits for the ProAct actuators are:
transient
current limit
Models I, II 13 A
Model III, IV 20.6 A
steady-state
current limit
7A
11.3 A
These limits can be biased up/down based on the electronics temperature (see
Current Limiting Based on Temperature below).
Transient
Limit
Steady State
Limit
Current Limiting Based on Temperature
An on-board temperature sensor is used to provide temperature monitoring, high
temperature alarming, and driver over-temperature protection. It monitors board
temperatures which are stored in a historical log. This log contains the
electronics temperatures of the unit over the lifetime of the driver. For more
detailed explanation, see Temperature Histogram in Chapter 6.
This temperature alarm is flagged if the set point is exceeded. This alarm set
point and delay are adjustable in the Configure: Unit Status menu.
The driver optionally provides actuator current limiting based on the electronics
temperature. Dependent on board and actuator thermal models, the software
reduces current as necessary to avoid conditions that would damage the device
due to extreme temperatures. Current limiting based on temperature begins
when the combined current and temperature environment exceeds steady state
continuous current at steady state mounting and ambient temperature (greater
than 105 °C—see temperature-based limits below). Depending on the current
and electronics temperatures, the unit may never reach a reduced level. This
option can be disabled in the Configure: Unit Status menu.
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Models' I and II Current Limits
Models' III and IV Current Limits
16
25
20
12
Current (Amps)
Current (Amps)
Transient
Transient Current
14
10
Steady State Current
8
6
4
15
Steady State
10
5
2
0
0
-50
0
50
100
Temperature (deg C)
150
-50
0
50
100
Temperature (deg C)
Figure 5-3. Current Limits
Nominal transient and steady current limits between 25 and 105 °C are 13 and 7
A, respectively, for models I and II (20.6 A and 11.3 A for models III and IV).
Communications
The driver has two communications ports; one optional CAN port and one RS-232
service port. The CAN port provides operation, setup, and monitoring capability.
The service port provides the capability to perform factory calibration and test,
customer/site configuration, tunable parameter and performance tuning, and
overall driver monitoring. The PC-based service tool allows the ProAct Digital Plus
software to be updated by Woodward factory or field service technicians.
CAN Communications
The optional CAN port supports positioning (position demand from CAN) of the
driver. It also supports ProAct Digital Plus monitoring of all shutdown and alarm
conditions as well as some system variables. The driver provides
communications via CAN, version 2.0B, with 29-bit identifiers. The protocol
complies with SAE J1939, but uses proprietary group extensions.
The initial CAN implementation is generic and adaptable to various customer
applications. The data rate is configurable from 250 kbps, 500 kbps, and 1 Mbps.
CAN communication failure diagnostics are provided and annunciated. Device
identification is available, using the CAN address discrete inputs, to facilitate
communication to multiple ProAct units on CAN.
The following are examples of parameters that are available on CAN.
Analog parameters including:
Set Position, Actual Position
Discrete parameters including:
Alarm Status, Shutdown Status, and all individual alarms and shutdowns
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Service Port (RS-232) Communications
The Service Port utilizes RS-232 communications and supports Woodward's
Servlink protocol for monitoring and tuning of software variables. The Service
Port is used for calibration, troubleshooting, and alarm/shutdown monitoring.
Additional functions available through this port include tuning, configuration, and
monitoring of the driver and actuator. It also supports configuration upload (send)
and download (receive) as well as the capability to install a new application
program in flash. If CAN is not used, the Service Port is the only means of
identifying/determining specific alarm and shutdown causes.
Service Tool
The Service Tool software resides on a PC (personal computer) and
communicates to the driver through the Service Port. The unit is typically in the
Normal (Running) mode. However, there are three additional modes available to
the customer for setup and monitoring: Configuration, Service, and User
Calibration. The Service Tool provided is Woodward Watch Window using the
Servlink DDE server. The service tool programs have password protection to
prevent inadvertent changes.
Power Up
System init done.
Self tests passed.
Valid Checksum.
User Cal
Keyword entered
Config Keyword
entered
Configure
Exit is True or
Low Power off
Normal
Application running
Exit is True
User
Calibration
(Service)
(no keyword)
Service
Figure 5-4. Operating Modes
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User Operating Modes
User-Calibration (Rigging)
The User Calibration mode of the Service Tool provides the capability to set the
min and max position to match the rigging of the actuator and valve. Both
automatic and manual procedures are available to perform this setup. This
calibration must be done prior to operation of the unit. Once performed, this
procedure stores the active min and max positions into non-volatile memory
where it is retained until a new calibration is performed (manual or automatic).
Configuration
The Service Tool provides the capability to make Configurable Parameter
adjustments when the unit is in a shutdown state. The unit must be in a shutdown
state to adjust configuration parameters. Configuration parameters can be
monitored at any time. Unit does not need to be shut down for configurable
parameter monitoring. The ProAct Digital Plus will do nothing—the current to the
actuator controller will remain off—until it has a valid configuration.
Service Mode Tuning
The Service Tool provides the capability to make field-tunable adjustments at any
time. A change to these parameters is not limited to a shutdown state (note: the
engine most likely is shut down during this time). Tunable adjustments are
available for parameters like input failure settings, position error setting, and
tracking error settings.
Service Mode Monitoring
The Service Tool provides the capability to monitor control values at any time.
Viewing and monitoring these parameters is available at any time and is not
limited to a shutdown state.
Monitoring is available for, but not limited to, the following parameters:
Electronics Temperature
Temperature Histogram
Alarms and Shutdowns (individual)
Alarm/Shutdown Event Log
Actual Position Monitor
Demanded Position
Actual Motor Current Monitor
Analog Input Monitor
PWM Input Monitor
CAN Demanded Position
Discrete Input Monitor
Discrete Output Monitor
Input Power Monitoring (24 V)
Internal Power Monitoring (12 V, –9 V, 5 V)
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Password Protection for Service Tool
Program changes and tuning/calibration are password protected. The password
is a simple ‘keyword’ password that is fixed and cannot be changed. It is
intended only to prevent inadvertent changes to the ProAct Digital Plus. One
fixed password is available per mode. This password is required only to make
changes (writes), program monitoring does not require a password. Monitoring
includes viewing configurable parameters, tunable parameters, alarm and
shutdown conditions, and control parameter monitoring.
There are passwords for the Configure Mode, Test Mode, Factory Calibration
mode, and User Stops Mode (Configure: Mode screen is shown below). These
password are listed in the Appendix.
Figure 5-5. Typical Service Tool Screen
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Chapter 6.
Diagnostics
General Information
There are a variety of diagnostics available in the ProAct™ Digital Plus, including
power-up self-test diagnostics and on-line diagnostics of alarm and shutdown
conditions. Driver alarm and shutdown conditions are monitored, logged, and
annunciated through the discrete output. The communications ports provide
complete fault diagnostic indications (excluding power-up faults).
Power-up Diagnostics
The ProAct Digital Plus provides power up self-test diagnostics. The power-up
diagnostics take less than one second to complete. This means the actuator is
active within one second of a power-up (when a main program is in flash
memory). A diagnostics error found during power-up will keep the output (HBridge) disabled. A power down and power-up are the only possible option for
clearing this error. During self-test the actuator is un-powered.
On-line Diagnostics
Once power-up tests are completed, the unit starts controlling and provides
on-line indication of alarms and shutdowns. The Discrete Output turns off to
indicate a shutdown or alarm condition. Individual Shutdown and Alarm
conditions can be monitored through the CAN or RS-232 communications links.
Shutdowns Detection and Annunciation
A shutdown condition forces the actuator to a predetermined position regardless
of the demanded position. The ProAct Digital Plus can be programmed to go to
one of three predetermined states when a shutdown condition is detected. A
shutdown condition can be configured to power-down (disable the current driver
to the actuator), go to min (0 %) position, or go to max (100 %) position. When
the shutdown condition no longer exists, the driver automatically returns to a nonshutdown state, following the Position Demand input command. The shutdown
condition does not require a “reset” command. Refer to the Diagnostics section
for a complete listing of shutdowns.
Alarms Detection and Annunciation
An alarm condition is a warning that the driver has determined that something is
not operating properly. The driver takes no additional action other than
annunciating and logging the alarm condition. When an alarm condition no longer
exists, the alarm event automatically returns to a non-alarmed state. The alarm
condition is non-latching. Refer to the Diagnostics section for a complete listing of
alarms.
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Temperature Histogram
The Temperature Histogram will provide historical electronics temperature
information based on the on-board temperature sensor. The histogram stores
values for over 20 years in non-volatile memory to retain the data on power loss.
The histogram logs the operational time of the electronics temperature in
seconds. The log is partitioned into 10 degree (Celsius) increment ranges from –
40 to +140 °C. The historical data is based on the time within each 10-degree
temperature band. The histogram is a permanent record of electronics
temperatures and cannot be cleared. The Service Tool is used to view the data in
the temperature histogram.
Event Log
The Event Log provides a historical logging of ProAct Digital Plus alarms and
shutdowns. It is capable of storing all events, along with the number of times that
event occurred and the relative time of the first occurrence. The log will store its
information in non-volatile memory to retain the data on power loss. The
resolution of the time stored is in hours. The Service Tool is used to view the
data in the event log. The log has a Reset/Clear command which clears the log
and all history. This command is only available through the Service Tool. The log
also stores the hour (time) of the last Reset/Clear command.
Power-up Diagnostics
The ProAct provides power up self-test diagnostics. An internal red LED displays
the status of the self-test (see Figure 2-5 for the location of this LED access).
When there is a valid main program in flash memory, minimal self-tests are
performed (to meet power up time requirement). When there is no main program
in the flash, an extensive set of tests is performed. This extensive test will more
thoroughly test the memory and hardware. The LED is steady ON red when the
unit is powered-up, and the LED turns OFF when all tests are successfully
completed. The LED will provide unique flash codes for any “failed” power-up
diagnostics. Note that the LED is internal and not visible when the driver is
assembled—it is provided for production testing only.
The power-up diagnostic testing takes less than one second to complete. This
means the actuator is active within one second of a power-up (when a main
program is in flash memory). A diagnostics error found during power-up will keep
the H-Bridge disabled. A power down and power-up are the only possible option
for clearing this error. During self-test the actuator is un-powered.
CODE: 01: No Application in memory fault
This is caused by the lack of an application program in the flash memory. The
application will not be run and the ProAct control will wait in this mode until a
valid program is downloaded. In this condition, the ProAct cannot transmit
information to the Service Tool or to the CAN link.
A valid application must be downloaded into memory before the unit will run.
This fault indication is not available to Servlink and is only indicated by a flash
code on the diagnostic LED. The red LED flash code consists of a continuous
on/off flashing sequence (0.1 s on and 0.1 s off).
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CODE: 02: EEPROM Error
This is caused by faulty hardware, which is checked during power up. This fault
indication is not available to Servlink, only a flash code on the diagnostic LED.
The red LED flash code consists of two quick ON (0.25 s) flashes followed by a
one second OFF time (see Figure 2-5 for the location of this LED access). This
sequence is repeated continuously.
The alarm is enabled when the following conditions are true:
EEPROM Write Fail—This error is set if writes to the main EEPROM fail. When
writing to the EEPROM, every byte is checked to ensure it is entered into the
EEPROM correctly. If the value read from the EEPROM is different from the
value written to the EEPROM, a new write is executed and a retry counter will be
incremented. After five retries, the EEPROM Error is set and the ProAct will shut
down.
EEPROM Read Fail—This error is set if reads from the EEPROM fail. The
EEPROM will always be read twice during operation. If the two values do not
match, a retry will be executed and a retry counter will be incremented. After five
retries, the EEPROM Error will be set and the ProAct will shut down.
Parameter Error—There is an error detected in the parameter set. Two
redundant sets of parameters are stored in non-volatile memory. During a read or
write cycle, the parameter values are checked. If either set is incorrect (as
indicated by their CRC16 value) the values from the correct set are copied into
the incorrect set. If both sets are incorrect the EEPROM Error is set and the
ProAct will shut down.
Parameter Checksum Error—The CRC checksum stored with the parameters
does not match the checksum of the parameters currently residing in non-volatile
memory.
The alarm is disabled when the power is removed and re-applied and the above
conditions go false. If cycling the power does not clear this fault, the control will
not run and must be returned for repair.
If this error occurs after a program download, this is an indication that the EE
structure has changed and the EEPROM must be initialized before the unit will
operate.
CODE: 03: RAM failed
Indicates the RAM read/ write is in error. This fault indication is not available to
Servlink, only a flash code on the diagnostic LED. The red LED flash code
consists of 3 quick ON (0.25 sec) flashes followed by a 1 second OFF time. This
sequence is repeated continuously.
This is caused by faulty hardware, which is checked during power up. This will be
checked by reading and writing a test pattern into RAM. If the test fails, the
ProAct will not start. A flash code on the diagnostic LED will annunciate the RAM
failure. In this condition, the ProAct cannot transmit information to the Service
Tool or to the CAN link. The unit needs to be returned to the factory to resolve
this RAM failure.
On-line Diagnostics
Once power-up tests are completed, unit will start controlling and on-line
indication of alarms and shutdowns are provided. The Discrete Output will open,
indicating a shutdown or alarm condition. Individual Shutdown and Alarm
conditions can be monitored through the CAN or RS-232 communications links.
The Servlink Variable listed with each individual diagnostic identifies the
parameter to be read in the Service Tool Watch Window program.
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Flash Codes
An LED flash code is available to identify the shutdown conditions detected by
the ProAct . The LED can only be viewed by removing the wiring access cover.
The flash codes for each diagnostic are identified both as the “code” number and
in the table at the end of this document (see Figure 2-5 for the location of this
LED access).
The diagnostic LED is used to give the user feedback on the error states of the
ProAct . The LED will produce a flash code to inform the user of an error. The
LED will be on solid when power is applied to ProAct or when the processor is
reset. The LED will go off when the ProAct goes to the running state. When shut
down, the LED flash code indicates the shutdown condition(s). There can be
several conditions that may cause a shutdown. The LED will display all shutdown
codes by cycling through all the shutdown flash codes one at a time.
Flash Code Generation
All flash codes will be a two-digit number. The LED will flash out the first digit,
pause, flash out the second digit, pause longer, and then continuously repeat the
flash code. For example, a code ‘34’ would flash as Figure 6-1 demonstrates.
0.25
Pulse
0.25
Delay
0.25
Pulse
0.25
Delay
. . . .
1 Sec
3
Code:
3 Sec
4
Figure 6-1. Typical Flash Code
Shutdown Detection and Annunciation
A shutdown condition is a condition that will force the actuator position to a
pre-determined known position regardless of the demanded position. The ProAct
can be programmed to go to one of three predetermined states when a shutdown
condition is detected. A shutdown condition can be configured to power down
(disable the current driver to the actuator), go to min (0 %) position, or go to max
(100 %) position. When the shutdown condition no longer exists, the driver
automatically returns to a non-shutdown state and follows the Position Demand
input command. The shutdown condition does not require a “reset” command.
Individual Shutdown Conditions
CODE: 12: Discrete Input Commanded Low Power Standby Mode
Servlink Variable: Service:Status Error—Shutdowns. DI LowPwr Stdby (12)
The Low Power Standby Mode was commanded by the opening of the Low
Power Standby discrete input. The discrete input must be closed to run.
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CODE: 13: RS232 (Servlink Service Tool) Commanded Shutdown
Servlink Variable: Service: Status Error—Shutdowns. RS-232 Shutdown (13)
The Shutdown mode is activated over the serial port with a shutdown command
using Watch Window (Configure: Mode). The actuator will perform the Shutdown
Action configured (for example, Min, Max, or Power Down). This can be cleared
by returning the Service Tool Shutdown Command to false or by cycling the
power on the unit.
CODE: 21: All Demands Failed
Servlink Variable: Service:Status Error—Shutdowns. All Demands Failed (21)
This is caused by a failure of all configured Position Demand Inputs. The Primary
and Backup (if used) position demands are both failed. The demand inputs are
determined to be failed and the problem must be corrected. If the inputs seem
proper, monitor the inputs in the Service Mode: Position Control and check the
failure settings in the Service Mode: Hardware Adjustments.
CODE: 22: A/D Converter Error
Servlink Variable: Service:Status Error—Shutdowns. A/D Converter Error (22)
This is caused by a failure of the analog to digital converter. The Queued A/D
Converter (QADC) did not complete all of it’s conversions for more than 300 ms.
The alarm is disabled when the power is removed and re-applied and the fault
condition goes false. If cycling the power does not clear this fault, it will not run
and must be returned for repair.
CODE: 23: Position Sensor Failed
Servlink Variable: Service:Status Error—Shutdowns. Position Sensor Failed(23)
This is caused by a failure of the internal position sensor. The internal position
sensor was out of range for more than 20 ms. This fault condition is latching and
remains true until power is removed and re-applied after the fault condition goes
away. If cycling the power doesn’t clear the problem, open the Low Power
Standby Mode discrete input and cycle power again and then run the User
Calibration (Adjust User Stops in the Service Mode) again. If this doesn’t clear
the fault, the sensor is bad and the unit must be returned for repair.
CODE: 24: Current Sensor Failed
Servlink Variable: Service:Status Error—Shutdowns. Current Fdbk Failed (24)
This is caused by a failure of the internal current sensor. The internal current
sensor was out of range for more than 40 ms. This fault condition is latching and
remains true until power is removed and re-applied after the fault condition goes
away. If cycling the power doesn’t clear the problem, open the Low Power
discrete input and cycle power again and then run the User Calibration (Adjust
User Stops in the Service Mode) again. If this doesn’t clear the fault, the sensor
is bad and the unit must be returned for repair.
CODE: 25: Configuration Error
Servlink Variable: Service:Status Error—Shutdowns. Config Error (25)
This is caused by an error in the configuration of the ProAct . To correct the error,
re-enter the Configure mode and make the appropriate correction. Refer to the
Configuration Error section in the Service Tools section of the manual for a
complete listing and description of all possible errors.
CODE: 26: Calibration Error
Servlink Variable: Service:Status Error—Shutdowns. Calibration Error (26)
Indicates a problem with the calibration. A step in the calibration was incorrectly
performed or an out of range value used or the precision reference voltage is out
of range. The Calibration mode must be re-entered and unit re-calibrated by a
trained service technician (requires Watch Window Professional).
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CODE: 27: Internal Watchdog Timeout
Servlink Variable: Service:Status Error—Shutdowns. Watchdog Timeout (27)
Internal run-time software watchdog timeout error of 1 second. If a watchdog
timeout error is detected the ProAct will shut down and attempt to restart the
ProAct control. If the unit remains in this mode, it must be returned for repair. It is
normal to get this alarm logged when a new version of the software is
downloaded into the ProAct control.
Alarms Detection and Annunciation
An alarm condition is a warning that the driver has determined that something is
not operating properly. The driver takes no additional action other than
annunciating and logging the alarm condition. When an alarm condition no longer
exists, the alarm event automatically returns to a non-alarmed state. The alarm
condition is non-latching.
Individual Alarm Conditions
The following is a detailed description of the ProAct alarm diagnostics.
CODE: 31 : Position Error
Servlink Variable: Service:Status Error—Alarms. Position Error Alert (31)
The Actual Position and Position Demand differ by more than the configured
position error for longer than the configured position error delay. This error is set
if the position command and the position feedback do not track closely enough
during transients. If the valve is able to move but the response becomes too slow
(for example, from contamination buildup), the ProAct actuator can still function
but the accuracy specification may not be met. There is a delay on the error
signal to prevent false errors during position transients. The position error
settings in the service mode may need to be adjusted—see the Service Mode:
Hardware Adjustments ‘Position Error Max’ and ‘Position Error Delay’ settings.
CODE: 41 : Primary Position demand signal fault
Servlink Variable: Service:Status Error—Alarms. Primary Demand Fault (41)
The Primary Demand signal is determined to be failed. This is caused by failure
of the input signal or hardware, which is continuously checked. Verify the input
signal. If the input seems proper, monitor the inputs in the Service Mode: Position
Control and check the failure settings in the Service Mode: Hardware
Adjustments.
CODE: 42 : Backup Position demand signal fault
Servlink Variable: Service:Status Error—Alarms. Backup Demand Fault (42)
The Backup Demand signal is determined to be failed. This is caused by failure
of the input signal or hardware, which is continuously checked. Verify the input
signal. If the input seems proper, monitor the inputs in the Service Mode: Position
Control and check the failure settings in the Service Mode: Hardware
Adjustments.
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CODE: 43 : Demand Not Tracking signal alert
Servlink Variable: Service:Status Error—Alarms. Tracking Error (43)
Primary and Backup demands differ by more than the configured tracking error
for longer than the configured tracking error delay and the backup demand signal
is configured for use. This is caused by failure of the input signal or the two
signals are either not tracking or not tracking closely enough. The tracking error
settings in the service mode may need to be adjusted (Demand Track Error (%)
and Demand Track Error Delay). This error can be disabled by setting the error
to 100 %. All PWM errors are disabled when PWM is not configured as a
demand source. This alert is only enabled when a backup demand is configured.
CODE: 51 : Analog Position demand input signal fault
Servlink Variable: Service:Status Error—Alarms. Analog Demand Fault (51)
Caused by failure of the input signal—indicates input failure/out of range
(low/high input current). The alarm is enabled when the Analog Input signal is
configured for use and is above or below the service mode failure settings for
longer than the failure delay setting. The analog demand is disabled until the
signal is restored. Verify the input signal. If the input seems proper, monitor the
input in the Service Mode: Position Control:Analog Demand and check the failure
settings (AnalogIn Fail Min and Fail Max) in the Service Mode: Hardware
Adjustments. The analog demand fault is disabled when analog is not configured
as a demand input.
CODE: 52 : PWM Frequency Error
Servlink Variable: Service:Status Error—Alarms. Pwm Freq Error (52)
Indicates a problem with the frequency of the PWM input signal—indicates input
frequency is out of range (low/high). The alarm is enabled when the PWM Input
signal is configured for use and is above or below the service mode failure
settings for longer than the failure delay setting. The PWM demand is disabled
until the signal is restored. Verify the input signal frequency. If the input seems
proper, monitor the input in the Service Mode: Position Control. PWM Demand
and check the failure settings (PwmIn Fail Min Freq and Fail Max Freq) in the
Service Mode: Hardware Adjustments. If Watch Window Professional is
available, can also check the PWM input frequency under the ‘Monitor.
Hardware’ category. All PWM errors are disabled when PWM is not configured
as a demand source.
CODE: 53 : PWM Duty Cycle Error
Servlink Variable: Service:Status Error—Alarms. Pwm Duty Error (53)
Indicates a problem with the duty cycle of the PWM input signal—indicates input
duty cycle is out of range (low/high). The alarm is enabled when the PWM Input
signal is configured for use and is above or below the service mode failure
settings for longer than the failure delay setting. The PWM demand is disabled
until the signal is restored. Verify the input signal frequency and duty cycle. If the
input seems proper, monitor the input in the Service Mode: Position Control.
PWM Demand and check the failure settings (PwmIn Fail Min Duty and Fail Max
Duty) in the Service Mode: Hardware Adjustments. If Watch Window
Professional is available, can also check the PWM input frequency and duty
cycle under the ‘Monitor. Hardware’ category. All PWM errors are disabled when
PWM is not configured as a demand source.
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CODE: 54 : PWM Signal Failure
Servlink Variable: Service:Status Error—Alarms. Pwm No Signal (54)
This is caused by failure of the input signal or hardware which is continuously
checked. Set if there are no pulses on the PWM input. This is needed because at
zero frequency, the frequency error will not be set. The alarm indicates no input
signal is detected for longer than the failure delay setting and the input signal is
configured. The alarm is disabled when the signal is restored. The PWM demand
is disabled until the signal is restored. Refer to the PWM Duty Cycle and
Frequency Error descriptions above for troubleshooting and possible
adjustments. All PWM errors are disabled when PWM is not configured as a
demand source.
CODE: 61 : CAN “Bus Off” Error
Servlink Variable: Service:Status Error—Alarms. CAN Bus Off Error (61)
This is caused by loss of communications on the CAN port which is checked
continuously. This error code is set if the CAN controller disconnects from the
bus (“bus off” condition) by tri-state drivers. In this condition, the CAN controller
does not monitor the CAN bus. The ProAct detects this “bus off” condition and
attempts to clear the fault condition automatically every 100 ms. Typical causes
for this condition are wiring problems on the CAN link, incorrect or missing
termination resistors, or electrical problems within the controller or driver. The
alarm is disabled once the CAN communications has recovered. The CAN
demand and all CAN commands are disabled until communications is restored.
All CAN errors are disabled when CAN is not configured as a demand source.
CODE: 62 : CAN controller not responding
Servlink Variable: Service:Status Error—Alarms. Can Dmd No Signal (62)
This is caused by loss of communications on the CAN port which is checked
continuously. There are no CAN Demand messages received for a specified
time. Set if there are no Demand messages received on the CAN link. This
detects a different problem than the Can Demand Too Slow error described in
the next section.
The alarm is enabled when CAN is configured for use and No CAN demand
messages are detected for longer than the service mode failure delay setting.
The alarm is disabled once the CAN communications has recovered. The CAN
demand and all CAN commands are disabled until communications is restored.
Verify the CAN Settings in the Configure Mode: Demand Setup (Data Rate and
Extensions) and the Device Address (based on the Can ID discrete inputs). All
CAN errors are disabled when CAN is not configured as a demand source.
CODE: 63 : CAN Demand Signal transmission too slow
Servlink Variable: Service:Status Error—Alarms. Can Dmd Too Slow (63)
This is caused by unacceptably slow communications on the CAN port which is
checked continuously. The frequency of the Demand CAN messages is below
the minimum service mode update rate. The ProAct reads the number of
messages received every 100 ms. If the CAN Fail Min (msg/sec) is set to 30,
during 100 ms ProAct receives 3 (30 divided by 10 samples/sec) or more
messages, there is no error. If there are less than 3 messages received in 100
ms, and if this occurs for the Can Fail Delay setting, the Can Demand Too Slow
error is set.
The alarm is enabled when CAN is configured for use and not enough CAN
demand messages are detected for longer than the service mode failure delay
setting. The alarm is disabled once the update rate on the CAN communications
has recovered. The CAN demand is disabled until communications fault is
cleared. All CAN errors are disabled when CAN is not configured as a demand
source.
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CODE: 71 : High Temperature Alert
Servlink Variable: Service:Status Error—Alarms. High Temp Alert (71)
This is caused by high temperature detected in the unit, which is checked
continuously. The alarm is enabled when the detected temperature is greater
than the configured temperature alarm set point for more than the configured
delay and is disabled when the conditions go false.
CODE: 72 : High Temperature Limit Protection Active
Servlink Variable: Service:Status Error—Alarms. Temp Limiting Active (72)
Indication that the temperature of the electronics has reached a point that
requires limiting the maximum current output to protect the electronics from
failure. The alarm is enabled when temperature limiting is configured for use and
the detected temperature is greater than the temperature limit set point of 105
°C. The alarm is disabled when the conditions go false for 300 ms.
CODE: 73 : Temperature Sensor Failure Alert
Servlink Variable: Service:Status Error—Alarms. Temp Sensor Fault (73)
This is caused by a failure in the temperature sensor hardware, which is checked
continuously. The alarm is enabled when the temperature signal is failed (sensor
counts <10 or >450 for longer than 1.5 seconds) and is disabled when the
conditions go false.
CODE: 81 : Supply Voltage (+24V) Low
Servlink Variable: Service:Status Error—Alarms. 24V Supply Low (81)
This is caused by an out of range input power source. The alarm is enabled
when the 24 V input voltage is below 11 V for more than one second or the
voltage is below 17 V for more than 40 seconds and is disabled when the
conditions go false.
CODE: 82 : Supply Voltage (+24V) High
Servlink Variable: Service:Status Error—Alarms. 24V Supply High (82)
This is caused by an out of range input power source. The alarm is enabled
when the 24 V supply voltage reads higher than 33 V (dc) for more than
5 seconds and is disabled when the condition goes false.
CODE: 83 : +12V out of range
Servlink Variable: Service:Status Error—Alarms. Supply 12Volt Error (83)
This is caused by faulty hardware. The 12-volt supply voltage is incorrect. An
internal +12 V supply voltage must be correct in order for the analog electronics
on the PCB to function properly. The CPU monitors this voltage and generates a
diagnostic if it is not in tolerance. The alarm is enabled when the 12 V reads less
than 10.8 V (dc) or higher than 13.2 V (dc) for more than 10 seconds and is
disabled when the conditions go false.
CODE: 84 : -9V out of range
Servlink Variable: Service:Status Error—Alarms. Supply Neg9Volt Error (84)
This is caused by faulty hardware. The –9 volt supply voltage is incorrect. An
internal –9 V supply voltage must be correct in order for the analog electronics on
the PCB to function properly. The CPU monitors this voltage and generates a
diagnostic if it is not in tolerance. The alarm is enabled when the –9 V reads less
than –10 V (dc) or higher than –8 V (dc) for more than 10 seconds and is
disabled when the conditions go false.
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CODE: 85 : +5V out of range
Servlink Variable: Service:Status Error—Alarms. Supply 5Volt Error (85)
This is caused by faulty hardware. The 5-volt supply voltage is incorrect. An
internal +5 V supply voltage must be correct in order for the analog electronics on
the PCB to function properly. The CPU monitors this voltage and generates a
diagnostic if it is not in tolerance. If the voltage is outside the operational range of
the processor the CPU will go into a reset state. While the CPU is in the reset
state the ProAct will not function. The alarm is enabled when the 5 V reads less
than 4.5 V (dc) or higher than 5.5 V (dc) for more than 10 seconds and is
disabled when the conditions go false.
CODE: 86 : A/D Reference Error
Servlink Variable: Service:Status Error – Alarms. A/D Reference Error (86)
This is caused by faulty hardware. The 5.0 V A/D precision reference voltage is
out of range. This is determined to be true if all voltage measurements are off
(24 V input power, 12 V, 5 V and –9 V).
CODE: 91 : Control is in a Non-Operating Mode
Servlink Variable: Service:Status Error—Alarms. NonOperating Mode (91)
The ProAct is in a non-operating mode. The alarm is enabled when the unit is in
the Adjust User Stops Mode or Configure Mode or Test Mode or Calibration
Mode and is disabled when the conditions go false.
CODE: 92 : Software Error detected
Servlink Variable: Service:Status Error—Alarms. Software Error (92)
A software error has been detected. The alarm is enabled when an internal
software coding error detected. The installed software application is invalid and
will need to be reinstalled to clear this fault. (It is advisable to return the unit to
the factory to have this new software application installed.)
CODE: 93 : EEPROM Error
Servlink Variable: Service:Status Error—Alarms. EEPROM Error (93)
This alarm is identical to the EEPROM Error (Code 02) detected during
initialization, only this error was detected during run-time. As opposed to holding
the unit in a shutdown state, when this error is detected the unit will remain in a
operational state. EEPROM changes that were attempted will not be made but
the unit will remain running with the changes held in RAM. However, the next
power-up will result in the loss of those changes and/or possibly a EEPROM
Error on power-up resulting in a non-operational state.
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Chapter 7.
CAN Details
Overview
This section describes the communication that will take place over the SAE
J1939 Data Link when the optional CAN (Controller Area Network)
communication link is used.
CAN Bit Timing
The default bit times for the ProAct™ Digital Plus are configured per SAE J1939
/11 section 3.14 (December 1994 version).
Source Address/Harness Code Strategy
There could potentially be four ProAct actuators on the same engine. Each
actuator would need to have its own source address. Rather than having
separate sets of ProAct software for each source address, a harness code
strategy has been implemented. The CAN address is set using the CAN ID Hi
and Lo discrete inputs. These switch inputs are pulled-up internally in the ProAct
actuator. The input will then either be left floating high, or be pulled down to
ground when the ProAct actuator is plugged in to the engine's wiring harness or
wired externally. The ProAct actuator will read these switch inputs and assign the
appropriate source address on power up. Changes to the discrete inputs after
power up will not be acknowledged until the next power up.
ProAct
CAN ID Hi Bit
CAN ID Lo Bit
Number
(Discrete In #3)
(Discrete In #2)
Assumed Source Address
of the ProAct valve
#1
#2
#3
#4
Floating high (open)
Floating high (open)
Pulled low
Pulled low
Floating high (open)
Pulled low
Floating high (open)
Pulled low
19
20
21
22
13h
14h
15h
16h
Configuration Strategy
There are over 25 configuration parameters available in the ProAct actuator.
These configuration parameters can either be downloaded as a file or individually
configured from the Configure Mode. Either way, configuration requires using a
PC connected to the ProAct serial port with a null modem cable. When required,
these parameters could be added as CAN PGNs and SPNs. However, at present
there are no plans to implement configuration over CAN until requested by a
customer.
CAN Extensions
To accommodate the differences in CAN implementation between customers, a
Configuration parameter (called CAN Extensions) is used to select the
appropriate set of extensions/PGNs/SPNs used.
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Extension Set 0
When the extensions setting is zero (0), all CAN transmissions are disabled.
When the extensions setting is greater than zero, the appropriate set of data is
transmitted/received over the CAN link. If CAN demand is used, CAN is
configured as primary or backup demand, then a setting of zero is not permitted
and results in a configuration error shutdown. If CAN demand is not used, then a
non-zero ‘extension’ setting will transmit only the data of the selected set.
Extension Set 1
Extension set 1 provides the following information sent over the CAN:

Actual and Desired Valve Position

Heart Beat Counter

ProAct Software Application Version

Alarms and Shutdowns (some grouping is provided to limit the number of
parameters)
Extension set 1 receives the following information from the CAN:

Position Demand
The following section lists all messages, which will be sent by the ProAct valve to
the speed control.
Set 1 Transmitted Parameters
Valve Position
Description
Transmission repetition rate
Data length
Data page
PDU format
PDU specific
Default priority
Parameter Group Number
Byte:
1
2
3...8
Value
100ms
8 bytes
0
255
251
7
65531
FFh
FBh
FFFBh
Actual valve position
Desired valve position
Reserved
Actual valve position—Measured position. A value of 0 % represents min and a
value of 100 % represents max.
Data length:
1 byte
Resolution:
0.4 % / bit, 0 offset
Range:
(0 to 100) % (scaled from 0 to FF hex)
Suspect Parameter Number:
1442
Desired valve position—Desired position. A value of 0 % represents min and a
value of 100 % represents max.
Data length:
1 byte
Resolution:
0.4 % / bit, 0 offset
Range:
(0 to 100) % (scaled from 0 to FF hex)
Suspect Parameter Number:
1442
Error Indicator set if:
None
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Heart Beat Counter
Description
Transmission repetition rate
Data length
Data page
PDU format
PDU specific
Default priority
Parameter Group Number
Byte:
1,2
3...8
Value
100 ms
2 bytes
0
255
31
6
65311
FFh
1Fh
FF1Fh
Heart Beat Counter
Reserved
Heart Beat Counter
Data length:
Resolution:
Range:
Suspect Parameter Number:
2 bytes
1 Count / bits, 0 offset
0 to 64255 Counts
1446-11
The Heart Beat Counter will count up.
Special action must be taken for the rollover from 64255 to zero.
Values above 64255 are not used, to be compatible with the J1939
specification.
Software version number
If the speed control needs the software version number it will use the request
message below.
Request message
Description
Transmission repetition rate
Data length
Data page
PDU format
PDU specific
Default priority
Parameter Group Number
Byte:
Byte:
Byte:
1
2
3
Value
On request
3 bytes
0
234
EAh
ProAct address
6
x
EAxxh
requested data PGN lsb
requested data PGN
requested data PGN msb
Response message
Description
Transmission repetition rate
Data length
Data page
PDU format
PDU specific
Default priority
Parameter Group Number
Byte:
Byte:
“*”.
50
Value
On request
8 bytes
0
254
FEh
218
DAh
6
65242
FEDAh
1
Number of software identification fields
2...8
Software version or identifier. Data must be delimited with ASCII
Pad data with FFh if less than 7 characters.
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Identification field
Data length:
Range:
1 byte
1
Software version number
Data length:
Range:
Resolution
Suspect Parameter Number:
Version Number Example:
7 bytes (maximum of 6 bytes of data plus "*")
ASCII characters, delimited by "*"
1 character/byte
234
“1.01*”
The ASCII data must be displayed without formatting.
Diagnostics from ProAct Actuator
The information communicated is limited to the current status of the diagnostics
and events that the ProAct actuator can perform within its scope. The status is bit
mapped to indicate the active or in-active state (see Bit Code Legend section).
Two bits are used for every fault condition to indicate the status. A proprietary
PGN will be used to communicate the faults.
Diagnostics/Events
The following Diagnostics and Events will be sent by the ProAct actuator in a
sequence.
Description
Transmission repetition rate
Data length
Data page
PDU format
PDU specific
Default priority
Parameter Group Number
Value
1 s*
8 bytes
0
255
16
6
65296
FFh
10h
FF10h
* See Transmission Rate for details.
Diagnostic information must also be available by request from the Speed Control.
Byte:
1..4
5...8
Diagnostics
Events
Bit code legend
The following diagnostics and events status will be sent by the ProAct actuator in
a sequence.
Bit code
00
01
10
11
Description
Inactive
Active
Reserved
Not Available
Bit position in a byte is “7 6 5 4 3 2 1 0”
Bit position 0 is least significant bit.
Example: Bit position 1 is “1” and all others bits are “0”, byte value is 2.
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Diagnostic codes
Diagnostics
J-1939 data frame
bit position
0,1
2,3
4,5
6,7
8,9
10,11
12 to 31
Shutdown – Commanded Shutdown
Shutdown—Position Demand Failure
Shutdown—Internal Failure
Alarm—Internal Fault
Alarm—Primary Demand Fault
Alarm—Backup Demand Fault
Reserved—sent as “1”
Commanded Shutdown includes the following shutdowns, which are individually
identified in the Service Tool:
Shutdown—Discrete In Low Pwr Standby
Shutdown—RS-232 Shutdown
Internal Failure includes the following shutdowns, which are individually identified
in the Service Tool:
Shutdown—All Demands Failed
Shutdown—A/D Converter Error
Shutdown—Posn Sensor Failed
Shutdown—Current Fdbk Failed
Shutdown—Configuration Error
Shutdown—Calibration Error
Shutdown—Watchdog Timeout
Primary or Backup Demand Fault includes (individually identified in the Service
Tool):
Alarm—Analog Input failure
Alarm—PWM Freq Error
Alarm—PWM Duty Error
Alarm—PWM No Signal
Alarm—Can Bus Off Error
Alarm—Can Dmd No Signal
Alarm—Can Dmd Too Slow
Alarm—Tracking Error
Internal Fault Alarm includes (individually identified in the Service Tool):
Alarm—Temp Sensor Fault
Alarm—12V Fault
Alarm—Neg9V Fault
Alarm—5V Fault
Alarm—Reference Voltage Error
Alarm—Software Error
Alarm—EEPROM Error
Event Codes
Events
Alarm—Position Error
Alarm—High Temp Alert
Alarm—Temp Limiting Active
Alarm—24 V Supply High
Alarm—24 V Supply Low
Reserved—sent as “1”
52
J-1939 data frame bit position
32,33
34,35
36,37
38,39
40,41
42 to 63
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Transmission Rate
The diagnostics messages are transmitted at a rate of once per second. This
message is sent only when there is at least one active fault or in response to a
request from the speed control.
All the diagnostic and event bits are set appropriately to indicate their current
status. The speed control will decode the bits and display the corresponding
diagnostic and event codes. The speed control also logs the diagnostic and
event codes as required by the application. The speed control makes the
decision to shut down or run depending on the application configuration, unless
the ProAct actuator has already shut down. The decision will be based on the
diagnostic and event classification made in the diagnostics document.
Set 1 Incoming CAN Commands
This section lists all messages, which will be sent by the speed control to the
ProAct actuator. The PGN for commanded position must be different for each
ProAct actuator and is determined by the ProAct CAN address harness.
Commanded Actuator Position (Demand to ProAct addresses 1–4)
Description
Transmission
repetition rate
Data length
Data page
PDU format
PDU specific
Default priority
Parameter Group
Number
Byte:
1...4
5...8
ProAct address
1 Value
ProAct address
2 Value
ProAct address
3 Value
ProAct address
4 Value
> 5 ms
> 5 ms
> 5 ms
> 5 ms
8 bytes
0
255 FFh
22 16h
1
65302
FF16h
8 bytes
0
255 FFh
23 17h
1
65303
FF17h
8 bytes
0
255 FFh
24 18h
1
65304
FF18h
8 bytes
0
255 FFh
25 19h
1
65305
FF19h
Actuator Position Demand
Reserved
Valve Position Demand
Data length:
Resolution:
Range:
Suspect Parameter Number:
4 bytes
2.56E-8 %/bit, 0 offset
(–5 to 105) % (scaled from 0 to FFFFFFFF hex)
1442
The resolution and range is a required deviation from the SAE
specification to meet application accuracy . Data is transmitted with
least significant byte first, per J1939.
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Arbitration
Typical Arbitration field (information only) using 29 bits:
Example using Heart Beat Counter in Extension Set 1
Priority
3 bits
Source
Address
PGN
1 bit 1 bit
8 bits
8 bits
8 bits
110 0 0 11111111 00011111 00010011
18
Heart Beat
Counter
Priority = 6
FF 1F 13
Heart Beat
Counter
PGN
ProAct #1
Source
Address
Figure 7-1. Typical Arbitration Field Example
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Chapter 8.
Service Tool
Description
The Service Tool software is used to configure, tune, and troubleshoot the
ProAct™ actuator. This chapter describes installation and use of the Service
Tool. It identifies the Servlink parameters available in the ProAct product that can
be viewed using the Woodward Watch Window Service Tool. It also provides
detailed information on configuring and setting up the ProAct actuator to the
customer-specific field application.
The Service Tool software resides on a PC (personal computer) and
communicates to the ProAct driver through the driver’s 9-pin service port. There
are modes available for various users including: Factory Calibration, Test,
Configuration, User Calibration, Tune, and Monitor modes (see Operating Mode
figure below). Factory Calibration and Test modes are internal Woodward-only
options; all else is available to the customer. The service tool modes are
password-protected to prevent inadvertent changes to the program. Tune and
Monitor capabilities are available at all times and are not password protected. For
safety purposes, the password protected modes can be entered only when the
unit is shut down. The unit can be shut down with a Service Tool command or by
opening the Low Power Standby Mode discrete input.
Configuration
The Configure mode provides general overall application information for the
driver. Since this actuator can be used in a variety of field applications, the
application-specific details are entered into the unit using the Configure mode.
Configurable parameters include actuator direction (CW/CCW) and
primary/backup demand sources. The Service Tool provides the capability to
make configurable parameter adjustments when the unit is shut down. CAN will
provide the capability to make Configurable Parameter adjustments to a limited
subset of parameters when the unit is shut down. The unit must be shut down to
adjust configuration parameters. Configuration parameters can be monitored at
any time. The unit does not need to be shut down for configurable parameter
monitoring. The ProAct actuator will do nothing—the current to the actuator
controller will remain off—until it has a valid configuration.
User Stops (Service)
The User Stops (also referred to as Rigging or User Calibration) mode of the
Service Tool provides the capability to set the min and max position to match the
rigging of the actuator and valve. Both automatic and manual procedures are
available to perform this setup. This calibration must be done prior to operation of
the unit. Once performed, this procedure stores the active min and max positions
into non-volatile memory where it is retained until a new calibration is performed
(manual or automatic). Also available in this mode is the capability to adjust and
test the actuator inertia dynamics setting.
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Start
Power Up
System init done.
Self tests passed.
Valid Checksum.
Configure
Factory Cal
Keyword entered
Config Keyword
entered
Exit is True or
Low Power off
Factory
Calibration
Exit is True
Normal
Application running
User Cal
Keyword entered
Test Keyword
entered
Exit is True
Exit is True
Test
(no keyword)
Debug
(no keyword)
User
Calibration
(Service)
Service
Figure 8-1. Operating Modes
Tuning/Adjustments (Service)
The Service Tool provides the capability to make field tunable adjustments at any
time from the Service Mode. A change to these parameters is not limited to a
shutdown state (Note: the engine most likely is shut down during this time).
Tunable adjustments are available for parameters like input failure settings,
position error setting, and tracking error settings.
Monitor (Service)
The Service Tool will provide the capability to monitor control values at any time
from the Service mode. Viewing and monitoring these parameters is not limited
to a shutdown state, but is available at any time.
Monitoring is available for, but not limited to, the following parameters:
Electronics Temperature and Temperature Histogram
Alarms and Shutdowns (individual)
Alarm/Shutdown Event Log
Position Control information (including actual position, current, demands)
Status and I/O monitoring
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Factory Calibration, Test, and Debug Modes
The Factory Calibration, Testing, and Debugging are performed using the
Woodward Watch Window Professional tool. The Factory Calibration mode
performs analog input and analog output hardware calibration in software
(calibrate out resistor tolerances). This includes calibration of Analog I/O (4 mA to
20 mA input, 20 mA to 180 mA input, 4 mA to 20 mA Output, Feedback sensor,
Current sensor). The unit will store all hardware calibration parameters in nonvolatile memory and retain the calibration independent of the application
software. The Test mode reads inputs and provides the capability to exercise the
outputs. The Debug mode provides additional parameters for monitoring and
troubleshooting.
Password Protection for Service Tool
The Configure, Test, User Stops, and Calibration modes are all provided with
password protection. This means that changes to the program and parameter
tuning/calibration are password protected. The password is a simple 'keyword'
password that is fixed and cannot be changed. This password is intended only to
prevent inadvertent changes to the ProAct actuator. This password is only
required to make changes (writes), program monitoring does not require a
password. Monitoring includes viewing configurable parameters, tunable
parameters, alarm and shutdown conditions, and control parameter monitoring.
Program Up-/Downloading
The Service Tool has the capability to save the current application parameter
settings to a file. It can also take a previously saved file and load it into the
ProAct. If a previously saved program is loaded, configuration and tuning are not
necessary. This obviously simplifies the steps required to get a new ProAct
actuator up and running.
How Do I Get Started?
The steps required to get started include:

Install the Service Tool (Watch Window/Servlink) software following the
installation steps described later in this chapter.

Configure the unit (see Chapter 9) or download a previously saved
configuration file.

Calibrate the User Stops and check dynamics adjustment (see Adjust User
Stops and Adjusting and Testing Actuator Dynamics in Chapter 9)—after the
ProAct actuator is installed, mounted, wired, connected to the valve, and
installation and wiring have been properly checked-out (Chapters 2 and 3).

Optionally, fine-tune application parameters (see Service Mode Parameters
in Chapter 9).
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Read this entire procedure before starting the prime mover.
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.
Getting Started
Installation Procedure
Install the Watch Window and Servlink server software using the setup program
on the CD or Disk 1. Alternatively, the Watch Window software can be
downloaded and installed from the Woodward internet site at:
www.woodward.com/software
What to Do Next
After the software is installed, connect a null modem communications cable
between the 9-pin connector on the ProAct control and an unused serial port on
your computer.
Start the Servlink communications server program on your computer
(Programs/Woodward/Watch Window Standard 1.6/Servlink Server). The
following is displayed when the program is executed.
Step 2 only needs to be performed one time initially. Once the ‘net’
file is read-in and saved, this step can be skipped and Watch Window
can be opened directly—see step 3.
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Initiate communications with the Woodward control as follows:
a. From the Servlink menu, select ‘File/ New’.
b. Verify the communications settings:
Set the ‘Port’ to match your serial port connection (e. g., COM1).
‘Mode’ is set to point- to- point for a single Woodward control.
Set the ‘Baud’ to 19200.
c. Select ‘OK’ to initiate communications. If a control is detected, ‘0’s and
‘1’s will stream across the screen, otherwise a Scan Error message will appear.
When the transfer is completed, the following is displayed.
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Change the Error settings on the Servlink Server to a 5 second timeout and 3
retries. Select Options / Error from the Servlink menu. Make sure the Save as
default is checked and select ‘OK’.
Save the network definition file by selecting ‘File/ Save’ from the Servlink menu.
Set an appropriate name for the file and select ‘Save’.
Start the Watch Window program (Programs/ Woodward/ Watch Window
Standard 1.6/ Watch Window Standard). The following appears on the screen.
Note: If step 2 was skipped (.net file was saved already), the Watch Window
program will first prompt the user for a Network Definition File.
Generate Program Screens using the blue ‘Q’ icon in the button bar or by
selecting ‘New Quick Inspector’ command from the Watch Window ‘File’ menu.
This will automatically generate Configuration and Service tab sheets in a new
Inspector Window. The tab sheet column widths can be adjusted, and the
window can be moved, resized, and saved, if desired. Refer to the Watch
Window Help for details.
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Watch Window Numeric Format
Versions of Watch Window older than 1.05.1 require a specific number format to
display values correctly. The required format uses a comma (‘,’) for digit grouping
and a decimal point (‘.’) for the decimal symbol. These settings can be adjusted
from the computer’s Control Panel / Regional Settings / Number tab sheet.
Watch Window 1.05.1 and newer does not require any special numeric
formatting.
Using Watch Window
Watch Window was developed by Woodward to be a Servlink client software
product that provides a generic PC interface to a Woodward actuator/control, and
is a very powerful setup, testing, tuning, and troubleshooting tool. Watch Window
provides a means of loading the application software into the unit, shutting down
and placing the unit in the configuration mode, saving values in the EEPROM,
and resetting the control. Application tunable values can be uploaded,
downloaded, and saved to a file.
Purpose
Watch Window is an engineering and troubleshooting tool that provides a window
into the control system. Watch Window is the primary troubleshooting tool for
Woodward controls that support the Servlink protocol.
Watch Window runs on a PC that is connected to the control system through a
serial communications port. The Engineering work station PC may be
permanently connected to the control or may be connected only as needed. The
communications server, Servlink I/O Server, is included in the same installation
with Watch Window.
Watch Window is a typical Microsoft Windows® application that provides a
powerful and intuitive interface. The menu structures are familiar to Windows
users. Variable navigation is provided through the Explorer window similar to the
Explorer in Windows.
Watch Window performs three primary functions:
Monitoring and Tuning of Control Variables—Watch Window presents
variables in a tabular format. The user chooses the variables to view at any given
time. Multiple pages of variables can be created, each with useful parameters for
various troubleshooting or tuning procedures. The user can toggle between
pages depending on the task being performed.
Control Configuration and Set Point Management—Watch Window can
upload or download all tunable variables from the control system. This feature
allows a user (e.g., fleet owner, distributor, packager) to upload (and save) all
tunable parameters from one control and download the same settings to other
controls for similar engine configurations.
Program Loading—Watch Window provides services to download a new
program to the control. This is available in the Professional version only.
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Watch Window User Interface
The Watch Window user interface is made up of three types of windows:
the Main Window
the Explorer
the Inspector
All Watch Window applications have only one main window and one Explorer
window. Each application can have as many Inspector windows as the user likes.
Main Window
The Main Window is the application-controlling window. It is used to close the
application. It is also used to control the Explorer's visibility and to create, control,
save and restore Inspectors. The Main Window is composed of a tool bar and a
menu.
Explorer
The Explorer is used to browse the set of variables available through the Servlink
Server, invoke commands on a control and view properties of a control. The
Explorer is composed of a set of tabbed sheets. Each sheet is associated with a
single control from a Servlink network. The sheet's tab is labeled with the
associated control's identifier.
Each sheet contains a tree view. The tree view displays the names of the
categories and blocks in a control's application program in a hierarchical
structure. The names at each level in the tree are listed in alphabetical order.
The standard version of Watch Window will not display Factory
Calibration, Test, and Debug values. Only the professional version
has this capability. Watch Window Standard only supports Service
and Configure modes.
Selected variables can be used in Copy & Paste or Drag & Drop operations in
order to add a variable to an Inspector. Variables can be selected using the
mouse (left click) or keyboard (arrow keys). Selecting categories or blocks
selects all of the fields underneath them.
Inspector
The Inspector is used to monitor and edit variables available on the control. The
Inspector is composed of a set of tabbed sheets. Each sheet contains a grid.
Each sheet's tab is labeled with a user-definable name. The user has the ability
to add and remove sheets using menu items and/or tool bar buttons in the Main
Window.
One or more variables can be selected using the mouse (left click) or keyboard
(arrow keys). If the user wishes to select multiple variables, they can do so by
performing one of these sequences:
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Select a variable, hold down the shift key, and arrow up or down until all of the
variables are selected.
Click on a variable, hold down the shift key, and click on the last variable in the
series that the user wishes to select.
Selected variables can be used in Cut, Copy & Paste, or Drag & Drop operations
in order to add a variable to an Inspector. If the selected variable is tunable or
configurable, the status bar will display the minimum and maximum value for that
variable. If multiple variables are selected, the minimum and maximum will not be
displayed for any of the selected variables.
The Inspector has a pop-up menu that has menu items that apply to the currently
selected sheet and/or variable. The Inspector can have its configuration saved
and restored. The Inspector can be closed by using the Main Window or by
clicking the standard windows close button.
Watch Window Decimal Places
The number of digits displayed after the decimal place displayed in Watch
Window can be adjusted from the Precision setting under the Watch Window
Options menu.
Watch Window Help
More help on using Watch Window is available and included with the installation
of the Watch Window product. Watch Window Help can be accessed from the
Watch Window ‘Contents’ drop-down window selection under the Help menu
located on the Main Window.
Software Version Identification
The Watch Window software version can found by selecting ‘About’ under the
Help menu. The ProAct software version information can be found by selecting
‘Properties’ under the Control menu. Refer to this information in any
correspondence with Woodward.
Watch Window Standard and Professional
There are two versions of the Watch Window software, Standard and
Professional. Watch Window Standard is provided with the ProAct control as a
Service Tool for Configuration, Tuning , and Monitoring. Watch Window Standard
supports only Service and Configure modes. The Standard version of Watch
Window will not display Factory Calibration, Test, and Debug mode values. Only
the professional version has this capability.
Watch Window Professional is available as a purchased upgrade, but is not
required for this product. In addition to providing Factory Calibration, Test, and
Debug mode access, the Professional version provides software download
capabilities for new or revised software versions. Like the Standard version, the
Professional version of Watch Window software can be downloaded and installed
from the Woodward internet site at:
www.woodward.com/software
A free trial period is included. This site can also be used to obtain license
authorizations.
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Chapter 9.
ProAct™ Parameter Setup
ProAct™ software setup consists of four steps: configuration of critical
operational parameters, calibration of the linkage between the ProAct control and
the actuator (User Calibration), tuning of the actuator dynamics, and optionally,
parameter fine-tuning in the Service Mode. No special command is required to
save parameters into memory—as soon as the new value is entered into the
associated Watch Window field, that value is in memory.
An unsafe condition could occur with improper use of these software
tools. Only trained personnel should have access to these tools.
Appropriate security permissions are required to perform these
functions.
The Service Tool is not included, but can be download from the
Woodward Internet website (www.woodward.com) or by ordering the
Watch Window Standard CD-ROM (1796-065).
Configure Mode
The Configure Mode parameters are found on the right-most tab sheets of the
Service Tool inspector created. The Configure mode is divided into three
sections: Mode is used to enable and disable the mode, Unit Setup provides
general setup information, and Demand Setup configures the primary and
backup demand sources.
Use the arrow buttons to view the Configure sheets and select the ‘Configure:
Mode’ tab sheet.
Make all desired Configure mode parameter changes. To change parameters on
the Configure tab sheets, the Woodward control must be in a safe state. The
following steps identify how to enter and exit the Configuration mode.
Entering Configure Mode
Select the Configure Mode tab sheet and shut down the driver by setting the Shutdown
Command value to ‘true’ or by opening the Low Power Standby Mode discrete input.
Enter the appropriate configure mode Password (1113) and either select ‘ENTER’
or click on the equals (=) box to the right of the password box. The ‘Enabled’ field
will display ‘true’ if the Configure Mode has been successfully entered.
Configure the unit by setting the Unit Setup and Demand Setup parameters to
the application specific values. Refer to the Configure Mode Details section of the
manual for details on these settings.
As changes are made to Configure and Service mode parameters,
they are automatically saved into non-volatile memory—no special
‘save’ command is required.
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Configuring the Unit (Configure Mode parameters)
Refer to the information provided later in this chapter for details on the Configure
Mode parameters. A program summary worksheet is provided in the Appendix as
an overview of all software settings in the ProAct control.
Exiting Configure Mode
Select the Configure Mode tab sheet and set the EXIT value to ‘true’.
Return the unit to a running (operational) state by setting the Shutdown
Command value back to ‘false’ or by closing the Low Power Standby Mode
discrete input.
The Service Mode / Unit Status will display ‘running’ if successful (refer to the
Service Mode Details section). If an error was made in the unit’s configuration, a
Config Error shutdown will hold the driver in a shutdown state. The exact cause
of the Configuration Error is identified on the Configure Mode tab sheet (see
Configuration Error section).
Figure 9-1. Configure Mode
Configuration Error
Upon completion of the configuration, a validity check is performed. If an error is
detected, the Config Error shutdown is issued and the unit will not run until it is
cleared. The cause of the Configuration Error can be determined from the Error
Code and Error Info values on the Configure Mode tab sheet.
Error Code
Error Info (displayed text)
0
No errors in configuration
101 Primary / Backup signal selection same
(the primary demand and backup demands are configured for the same source)
102 Invalid primary demand signal selection
(the primary demand selection is configured for an out of range value)
103 Invalid backup demand signal selection
(the backup demand selection is configured for an out of range value)
104 Actuator Inertia setting value too large
(the actuator inertia setting selection is configured for an out of range value)
105 Invalid Actuator type selection
(the actuator type is configured for an out of range value)
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106 Invalid PwmIn max/min duty values
(the PWM demand input setting for min duty cycle must be less than the max value)
107 Invalid AnalogIn max/min values
(the analog input demand input setting for min must be less than the max value)
108 CAN Extensions must be non-zero
(the CAN Extensions setting cannot be zero when CAN is configured as a demand
signal. An Extension setting of zero disables the CAN transmissions.)
Configure Mode Parameters
Overview
The Configure Mode is used to set up the parameters for the specific application
of the ProAct control. For example, the direction of shaft rotation, type of
actuator, and primary/backup demand selections are set in the Configure mode.
This mode can be accessed at any time but parameters can only be changed
when the unit is shut down and the password is entered (see Password and
Enabled parameters in the Mode category).
An unsafe condition could occur with improper use of these software
tools. Only trained personnel should have access to these tools.
Appropriate security permissions are required to perform these
functions.
Configure Mode (Configure Mode Access)
The Mode category provides the access to change parameters in the Configure
Mode. Refer to Figure 9-1. It also provides an exit command, gives mode status,
and identifies any errors made in configuration.
Password
dflt =0
Password input command for the Configure mode. To enter a value, highlight or
delete the default value (‘0’) and use the keypad to enter the numeric password.
The input is accepted when the enter key is pressed or the equals sign to the
right of the input is selected. When entered, the password returns to zero. If
accepted and the unit is shut down, the ‘Enabled’ indication will be true. Refer to
the Appendix for Service Tool passwords.
Enabled
(status indication only)
Configure Mode Enabled Indication (true/false). Parameter is true when the
mode is enabled – this indicates Configure mode parameters can be changed.
When false, parameters can only be viewed – not adjusted.
Exit
dflt = false (momentary true command only)
Exit command. Set to true to exit the Configure mode. This disables the ability to
make changes to parameters in this mode. The ‘Exit’ parameter automatically
returns to false when the exit is completed.
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Error Code (status indication only)
Integer Indication of the status of the configuration (see also Error Info). An error
in the configuration will not allow the actuator to operate and will result in a
Configuration Error Shutdown.
Error Code Interpretation (same as Error Info below)
0
101
102
103
104
105
106
107
108
No errors in configuration
Primary / Backup signal selection same
Invalid primary demand signal selection
Invalid backup demand signal selection
Actuator Inertia setting value too large
Invalid Actuator type selection
Invalid PwmIn max/min duty values
Invalid AnalogIn max/min values
CAN Extensions must be non-zero
Error Info
(status indication only)
String Indication of the status of the configuration (see also Error Code). An error
in the configuration will not allow the actuator to operate and will result in a
Configuration Error Shutdown (see information on shutdowns).
Shutdown Command
dflt = false (false, true)
RS232 Command to shut the actuator driver down. Refer to shutdowns.
Configure: Unit Setup
The Unit Setup category sets critical actuator and controller information. Refer to
Figure 9-2. Additional actuator parameters are available in the Service Mode
(see ‘Hardware Adjustments’).
Actuator Type
dflt = 3 (1=ProAct1, 2=ProAct2, … 4=ProAct4)
ProAct Actuator Type configuration. This is set to the appropriate ProAct actuator
(e.g. ProAct Model 4 would be set to ‘4’).
Figure 9-2. Configure Mode: Mode
Actuator CCW Direction
dflt = false (false=CW, true=CCW)
ProAct Actuator Direction configuration—clockwise vs. counter-clockwise—as
seen from the shaft end of the actuator.
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Actuator Inertia Setting
dflt =0 (range 0–25)
Actuator/valve inertia setting. This setting is available for systems with higher or
lower inertia than the default as indicated by excessive shaft movement. A zero
(0) setting is basically for an unconnected shaft, whereas, increasing the setting
implies a higher inertia in the system. This parameter can also be tuned and
tested in the Service Mode—see Adjusting and Testing Actuator Dynamics in the
Adjust User Stops section for details (see Figure 9-9 for more details).
High Friction System
dflt =false (false, true)
Internal Disturbance Observer Controller (dobs) Enable command. Normally set
to false, only needed in high friction systems. This parameter can also be tuned
in the Service Mode to determine if it is needed—see Adjusting and Testing
Actuator Dynamics in the Adjust User Stops section for details (see Figure 9-9 for
more details).
DiscreteOut Alarms Enabled
dflt=true (false, true)
Discrete Output configuration setting. When false, only Shutdowns will activate
the discrete output. When true, any alarm or shutdown condition will activate the
discrete output.
Discrete Out Includes Runenable [Run/Enable]
dflt=true (false, true)
(This parameter only available with ProAct Software Version 2.10 or later)
(Check the version number under Service: Unit Status:)
When set to true, when the Run Enable Discrete Input (Low Power Standby
Mode) contacts are opened, the Status Output will also open. When set to false,
the condition of the Run Enable (Low Power Standby Mode) contacts will not
affect the Status Output.
Run Enable – Closed to Run
dflt=true (false, true)
(This parameter only available with ProAct Software Version 2.20 special
firmware Woodward part number 5418-2590)
(Check the version number under Service: Unit Status:)
When set to true, the run enable contacts will be closed for run mode, and open
for Low Power Standby Mode. When set to false, the run enable contacts will be
open for run mode, and closed for Low Power Standby Mode.
Shutdown Action
dflt = 3 (1,3)
Select the action to be performed when a shutdown condition is detected.
Selection options: 1=Min, 2=Max, 3=Pwr Down. (refer to Shutdown description
TBD).
Temp Alarm SP (°C)
dflt = 95 °C (50, 150)
High Temperature Alarm set point in degrees Celsius. This alarm is based on the
internal electronics temperature. Refer to the alarms section for details.
Temp Alarm Delay (sec)
High temperature alarm delay in seconds.
dflt = 1 sec (0, 10)
Temp Protect Enable
dflt =true (false, true)
Temperature Protection Configuration. This enables current limiting based on
temperature and is a combination of temperature protection and compensation.
When set to true (recommended), protection is provided to limit the drive current
output when the internal actuator temperature exceeds the absolute failure
levels. When set to false, this protection is bypassed. An alarm is logged when
absolute failure protection temperature limiting is active. The same algorithm not
only limits the current at very high temperatures, but allows additional current at
very low temperatures as well (refer to Current Limiting based on Temperature
description in Chapter 5).
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Figure 9-3. Configure Mode: Unit Setup
Configure: Demand Setup
The Demand Setup sets the ProAct control’s primary and backup demands.
Refer to Figure 9-4. Additional demand parameters are available in the
Adjustments Mode.
Demand—Primary Source
dflt = 3 (1, 3)
Select the source of the primary demand input. Selection options: 1=CAN,
2=PWM, 3=Analog.
Demand—Backup Source
dflt = 2 (0, 3)
Select the source of the backup demand input. Selection options: 0= Not Used,
1=CAN, 2=PWM, 3=Analog (Primary and Backup demand sources must be
different).
AnlgIn 20 Min Value (mA)
dflt=4 mA (range 0.0–25)
Analog Input Minimum Demand Value in mA. This setting corresponds to the
milliamp signal that would demand the actuator to be fully closed (0 %) (should
be less than the ’AnlgIn 20 Max Value (mA)’ setting).
AnlgIn 20 Max Value (mA)
dflt=20 mA (range 0.0–25)
Analog Input Maximum Demand Value in mA. This setting corresponds to the
milliamp signal that would demand the actuator to be fully opened (100 %)
(should be greater than the ’AnlgIn 20 Min Value (mA)’ setting).
AnlgIn 200 Min Value (mA)
dflt= 20 mA(range 0.0–200)
Analog Input Minimum Demand Value in mA. This setting corresponds to the
milliamp signal that would demand the actuator to be fully closed (0 %) (should
be less than the ’AnlgIn 200 Max Value (mA)’ setting).
AnlgIn 200 Max Value (mA)
dflt=180 mA (range 0.0–200)
Analog Input Maximum Demand Value in mA. This setting corresponds to the
milliamp signal that would demand the actuator to be fully opened (100 %)
(should be greater than the ’AnlgIn 200 Min Value (mA)’ setting).
CAN DataRate
default = 1(1, 3)
CAN data rate setting in kbps. Selection options: 1=250, 2=500, 3=1000 kbps.
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CAN Extensions
default = 1 (0, 1)
CAN Extension Configuration. This determines the messages of the CAN
communications. The ProAct uses J1939 CAN but this setting sets up the actual
Parameter Group Numbers (PGNs) and Suspect Parameter Numbers (SPNs) to
be used over the comm link. Selection options: 0=Disable Can communications,
1=Set#1, 2=Set#2, etc. (must be greater than zero if CAN demand is configured).
PwmIn Min Duty (%)
default = 10 % (range 10–90)
PWM Minimum actuator position Duty Cycle setting in percent. This setting
corresponds to the duty cycle that would demand the actuator to be fully closed
(0 %) (must be less than the ’PwmIn Max Duty (%)’ setting).
PwmIn Max Duty (%)
default 90 % (range 10–90)
PWM Maximum actuator position Duty Cycle setting in percent. This setting
corresponds to the duty cycle that would demand the actuator to be fully open
(100 %) (must be greater than the ‘PwmIn Min Duty (%)’ setting).
PwmIn Frequency (Hz)
Nominal PWM signal frequency in hertz.
dflt 1000 Hz (100–3000)
PwmIn Invert Input Signal
dflt =false (false, true)
Invert PWM Signal option. This configuration setting is available for systems that
do not have a pull-up in their PWM output (refer to the hardware PWM section for
details). This setting inverts the PWM input values to read the percentage of the
time low rather than the percentage of the time high.
Figure 9-4. Configure Mode: Demand Setup
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Adjusting User Stops and Dynamics
Introduction
The User Calibration mode of the Service Tool provides the capability to set the
min and max position to match the rigging of the actuator and valve. Both
automatic and manual procedures are available to perform this setup. This
calibration must be done prior to operation of the unit. If this procedure is not
done, the actuator will be defaulted such that (0 to 100) % position demand will
correspond to 0–75 degrees rotation. Refer to Figure 9-5. Once the user
calibration is performed, this procedure stores the active min and max positions
into non-volatile memory where it is retained until a new calibration is performed.
In addition, this mode can be used to verify the setup/calibration by providing a
manual stroking mechanism.
An improperly calibrated control could cause an overspeed or other
damage to the prime mover. To prevent possible serious injury from
an overspeeding prime mover, read this entire procedure before
starting the prime mover.
An unsafe condition could occur with improper use of these software
tools. Only trained personnel should have access to these tools.
Appropriate security permissions are required to perform these
functions.
To enter the User Calibration mode, the unit must be shut down and a password
must be entered. For an overview of the User Calibration, refer to the attached
flowcharts (Figures 9-8 and 9-9). Refer to Figure 9-7 for a visual of the
parameters available in the Service Tool.
Engine/Site Specific Stroke
Min
Stop
0
Overall PAG2 Stroke
Max
Stop
75 degrees
Figure 9-5. Min/Max Stops Relative to the Overall Travel
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Procedure to Adjust Stops and Dynamics
1. Connect PC to ProAct using an RS-232 Null Modem cable.
2. Run Servlink on the PC and connect to the ProAct control. Refer to the
Service Tool chapter for details on Servlink setting and connection in the
Getting Started section.
3. Open Watch Window or alternative programming tool on the PC.
4. Shut down the ProAct by either issuing a Shutdown Command from the PC
(on the Unit Status tab sheet) or by opening the ProAct Low Power Standby
Mode Discrete Input. Either method puts the unit in a shutdown state, which
is a permissive for the Adjust User Stops mode.
5. Enter the Adjust User Stops Password (Mode Password) from the Service:
Adjust User Stops tab sheet. The ProAct will provide feedback that the user
stops calibration mode has been successfully entered through the
Operational Mode and Mode Enabled indications.
6. Select the desired calibration mode. There are 2 modes, a manual stroking
mode and an automatic mode. Refer to Figures 9-8 and 9-9. If the Auto
mode is selected, steps 7 through 11 will occur automatically without any
user input required. Auto Mode is enabled by setting “Auto Execute” to true.
7. There are two methods to manually move the output between min and max
position: by hand or by using the Manual Set Position. To use the Manual Set
Position, the Manual enable must be set to true. Using the Manual Set
Position to position the ProAct, decrease the demand setting until the
actuator is positioned at the minimum stop or, by hand, push the output into
the min stop.
8. Set the At Min Position parameter to true to allow the Control to record the
Min position setting.
9. Increase the Manual Set Position setting until the actuator is positioned at the
maximum stop or, by hand, push the output into the max stop.
10. Set the At Max Position parameter to true to allow the Control to record the
Max position setting.
11. When both Min and Max have been successfully calibrated, set the Enable
Manual Stroke back to false (if a Manual Calibration is enabled). If
successful, the Calibration Status will indicate the calibration is complete.
The status will indicate ‘failed’ if the calibration is unsuccessful.
12. Verify Calibration. This can be done by hand by moving the rack from min
to max and observing the position readout (Service Tool or analog out) or by
stetting the Manual Enable to true and positioning the output using the
Manual Set Position variable.
13. Adjust Dynamics. Adjust the Actuator Inertia Setting for proper system
performance. Increasing the setting implies a higher inertia in the system and
results in a higher gain in the actuator. Verify the setting with the Actuator
Inertia Test Execute command. Refer to Table 9-1 for an approximate inertia
setting based on lever size.
14. Optionally, set the offset (bias) desired at each stop. The Min Stop Bias and
Max Stop Bias parameters are available in the Hardware Adjustments to
basically provide an electrical stop within the user calibrated stop settings.
This offset is in degrees of travel and can be adjusted anytime. Refer to
Figure 9-6 and Service Mode: Hardware adjustments later in this chapter.
15. When calibration is complete, set the Mode Exit to true to return to the
previous (Shutdown) mode.
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Figure 9-6. Electrical Stop Adjustments Relative to the Mechanical Min and Max
Stops
Figure 9-7. Service Mode: Adjust User Stops
Service: Adjust User Stops
(must be shut down and password entered)
This category provides the access to change parameters in the Adjust User
Stops Mode. Refer to Figure 9-7. It provides both automatic and manual means
of setting the stops, inertia setting and testing capability, and exit command,
gives mode status, and identifies an errors made in configuration.
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Mode Password
dflt =0
Password input command for the Adjust User Stops mode. To enter a value,
highlight or delete the default value (‘0’) and use the keypad to enter the numeric
password. The input is accepted when the enter key is pressed or the equals
sign to the right of the input is selected. When entered, the password returns to
zero. If accepted and the unit is shut down, the ‘Enabled’ indication will be true.
Refer to the Appendix for Service Tool passwords.
Mode Enabled
(status indication only)
Adjust User Stops Mode Enabled Indication (true/false). Parameter is true when
the mode is enabled—this indicates Adjust User Stops mode parameters can be
changed. When false, parameters can only be viewed—not adjusted.
Mode Exit
dflt = false (momentary true command only)
Exit command. Set to true to exit the Adjust User Stops mode. This disables the
ability to make changes to parameters in this mode. The ‘Exit’ parameter
automatically returns to false when the exit is completed.
Auto Execute
dflt = false (momentary true command only)
Command to Execute the Automatic ‘stop finder’ procedure. When set to true,
the output moves to both minimum and maximum positions and determines the
stops automatically. The Status string indications the present execution step. The
command is automatically set back to false when the stops are set.
Auto Status—String indication of the automatic user stop procedure.
–1= Failed
0 = Disabled
1 = Enabled
2 = Looking for Min Stop
3 = Looking for Max Stop
4 = Stops Set
Auto Status Int—Integer indication of the Auto Status string (see above).
Manual Enable
dflt = false
Command to enable the manual user calibration. When true, the Manual Set
Position (%) is actively controlling the driver output to the commanded position.
This mode can also be used to stroke the output.
Manual Set Position (%)
default 50 % (–10 to 110)
Manual position demand. This demand setting is active when the Manual Mode
is enabled. Can be used to both set the stops and to stroke the actuator output.
Manual Status—String indication of the manual user stop procedure.
–1= Failed
0 = Disabled
1 = Enabled
2 = Min Stop Set
3 = Max Stop Set
Manual Status Int—Integer indication of the Manual Status string (see
above).
Manual—At Min Posn
dflt = false (momentary true command only)
Command to indicate minimum position is reached. This sets the 0 % (min)
position for all position demand signals.
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User Calibration Operator Flow - Auto Mode
PAG2 must be in a shutdown state
START
Servlink Variables
Mode Enabled
Mode Password
Auto Execute
Auto Status
Auto Status Int
Mode Exit
Enter the Mode
Password
Password is cleared.
No
Is
Password
OK?
Yes
Status Definitions
-1 -- Failed
0 -- Disabled
1 -- Enabled
2 -- Looking foir Min
3 -- Looking for Max
4 -- Stops Set
The Control sets OperationalMode =
UserCalibration, Status=Enabled,
Password is cleared.
Set Enable Manual
Stroke to true.
Set Auto Execute
to true.
The Control saves all
User Calibration
parameters and exits
the UserCal Mode.
Exit Calibration Mode is
selected.
Enables the Manual
stroke functionality.
The Control moves the
position demand to
maximum.
No
Actual
Position is >
50%
Yes
The Control moves the
position demand to
minimum.
The Control determines
the position is at
maximum once the
feedback stops moving
and samples the
feedback.
The Control determines
the position is at
minimum once the
feedback stops moving
and samples the
feedback.
The Control moves the
position demand to
minimum.
The Control moves the
position demand to
maximum.
The Control determines
the position is at
minimum once the
feedback stops moving
and samples the
feedback.
The Control determines
the position is at
maximum once the
feedback stops moving
and samples the
feedback.
The Control sets the
Status=Stops Set if the
calibration was
successful, otherwise it
is set to Failed;
ExectureAutoStroke is
reset to false.
Figure 9-8. Auto Stroke Mode Flowchart
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User Calibration Operator Flow - Manual Mode
PAG2 must be in a shutdown state
Servlink Variables
Mode Enabled
Mode Password
Manual Enable
Manual - At Min Posn
Manual - At Max Posn
Manual Status
Manual Status Int
Mode Exit
START
Enter the Mode
Password
No
Password is cleared.
Is
Password
OK?
Yes
Status Definitions
-1 -- Failed
0 -- Disabled
1 -- Enabled
2 -- Min Stop Set
3 -- Max Stop Set
The Control sets
OperationalMode = UserCalibration,
Password is cleared.
Set Auto Execute to
true.
Enables the Auto
Mode stroke
functionality.
Set Manual Enable
to true.
The Control saves all parameters
and exits the Mode.
Set Mode Exit to true.
The Control moves to
the position demand set
by the Manual Set
Position parameter.
Decrease the Manual
Set Position setting
until the actuator is
positioned at the
minimum stop.
Increase the Manual
Set Position setting
until the actuator is
positioned at the
maximum stop.
Set the At Min Position
parameter to true to
record the Min stop
position setting.
Set the At Max Position
parameter to true to
record the Max stop
position setting.
The Control checks the
feedback, if not within
range, the Status is set
to FAIL.
The Control checks the
feedback, if not within
range, the Status is set
to FAIL.
Adjust the Manual Set
Position setting to verify
actuator stop settings.
Set Enable Manual
Stroke to false.
The Control sets the
Status=Disabled if the
calibration was
successful, otherwise it
is set to Failed.
Figure 9-9. Manual Stroke Mode Flowchart
Manual—At Max Posn
dflt = false (momentary true command only)
Command to indicate maximum position is reached. This sets the 100 % (max)
position for all position demand signals.
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Adjusting and Testing Actuator Dynamics
Actuator dynamics are set in the Configure Mode, but can also be adjusted in the
Adjust User Stop mode. There is only one adjustable dynamics parameter, it is
the Actuator Inertia Setting (see Figure 9-7). To change this parameter, the User
Stop mode must be enabled.
Actuator Inertia Test Execute
Once changed, it is recommended the setting be tested. A quick stability check
can be done by selecting the ‘Actr Inertia Test Execute’ command. This provides
a short actuator positioning sequence and can be used to verify the Inertia
Setting. The sequence goes to 30 % travel for 3 seconds, then goes to 70 % for
3 seconds and back to 30 % for 3 seconds, concluding the test. If instability is
detected, the test can be aborted by setting the Execute command back to false.
In general, if the Inertia Setting is too high the output will have a high frequency
oscillation and too low the frequency of oscillation will be much slower or
response will be sluggish.
Actuator Inertia Setting
dflt =0 (range 0–25)
Actuator/valve inertia setting. This setting is available for systems with higher or
lower inertia than the default as indicated by excessive shaft movement. A zero
(0) setting is basically for an unconnected shaft, whereas, increasing the setting
implies a higher inertia in the system. Refer to Table 9-1 for an approximate
Inertia Setting value based on lever size.
High Friction System
dflt =false (false, true)
Internal Disturbance Observer Controller (dobs) Enable command. Normally set
to false, only needed in high friction systems. As a general rule-of-thumb, when
more than 2 A of current are required to move the actuator then a true setting will
help with controllability.
Width * Thickness (of one lever)
[inches; 1 inch = 25.4 mm]
0.25
0.50
0.75
1.00
1.50
2.00
Lever Length [inches]
2.00
0
1.00
2.00
2.00
3.00
4.00
2.50
1.00
2.00
3.00
4.00
5.00
6.00
3.00
2.00
3.00
5.00
6.00
7.00
8.00
3.50
3.00
5.00
6.00
7.00
9.00
10.00
4.00
4.00
6.00
8.00
9.00
11.00
12.00
4.50
5.00
7.00
9.00
10.00
12.00
13.00
5.00
6.00
9.00
10.00
12.00
14.00
15.00
5.50
7.00
10.00
12.00
13.00
15.00
16.00
6.00
8.00
11.00
13.00
14.00
16.00
18.00
6.50
9.00
12.00
14.00
15.00
17.00
19.00
7.00
10.00
13.00
15.00
16.00
18.00
20.00
8.00
12.00
15.00
17.00
18.00
20.00
22.00
9.00
13.00
17.00
19.00
20.00
22.00
23.00
10.00
15.00
18.00
20.00
22.00
24.00
25.00
12.00
18.00
21.00
23.00
24.00
—
—
Table 9-1. Approximate Inertia Setting for Two Identical Steel Levers
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Service Mode Parameters
Overview
The Service Mode is used to Adjust User Stops, tune application parameters,
and monitor ProAct actuator status. Parameters in this mode can be accessed
and changed at any time (with the exception of Adjusting User Stops).
Tuning Application Parameters
All control parameters in the Service mode that can be tuned are found under the
Hardware Adjustments tab sheet.
Service: Hardware Adjustments
The hardware adjustments tab sheet contains all the parameters that can be
used to “fine tune” the ProAct control to the specific application. Refer to Figure
9-10.
An unsafe condition could occur with improper use of these software
tools. Only trained personnel should have access to these tools.
Figure 9-10. Service Mode: Hardware Adjustments
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AnalogIn 20 Fail Min (mA)
dflt = –1 mA (–1 to 12.5)
Value at which the analog input will be determined as failed, for the 20 mA
analog input range. A failure is determined if the input is below the ‘Fail Min’
milliamp level for the ‘AnalogIn Fail Delay’ time. A value of ‘–1’ disables the
minimum current failure.
AnalogIn 20 Fail Max (mA)
dflt = 26 mA (12.5 to 26)
Value at which the analog input will be determined as failed, for the 20 mA
analog input range. A failure is determined if the input is above the ‘Fail Max’
milliamp level for the ‘AnalogIn Fail Delay’ time.
AnalogIn 200 Fail Min (mA)
dflt = –5 mA (–5.0 to 100)
Value at which the analog input will be determined as failed, for the 200 mA
analog input range. A failure is determined if the input is below the ‘Fail Min’
milliamp level for the ‘AnalogIn Fail Delay’ time. A value of ‘–5’ disables the
minimum current failure.
AnalogIn 200 Fail Max (mA)
dflt = 250 mA (100 to 250)
Value at which the analog input will be determined as failed, for the 200 mA
analog input range. A failure is determined if the input is above the ‘Fail Max’
milliamp level for the ‘AnalogIn Fail Delay’ time.
AnalogIn Fail Delay (sec)
Analog input failure delay in seconds.
AnalogIn Filter
Lag-tau filter adjustment on the analog input.
default = 0.1 sec (0.01 to 10)
default = 0.01 (0.0 to 1.0)
AnalogOut Offset (mA)
default = 0 mA (–2 to 24)
Offset adjustment, in milliamps, on the analog output current.
AnalogOut Gain
default = 1 ( -1.0 to 1.5)
Gain adjustment on the analog output current. The gain is based on the actual
position, at 0 % the gain adjustment has no effect. Output in milliamps = (Actual
position in % + 4mA)(Gain) + Offset. Note: The analog output can be reversed
(20-4 mA), if desired, by setting the gain to –1 and offset to 24.
CanIn Fail Min (msg/s)
default = 30 (10 to 100)
Failure adjustment for the CAN demand input. This setting is the minimum
number of messages per second that the ProAct will receive before a failure will
be issued. CAN failure is indicated when the messages drop below the ‘Fail Min’
value for the ‘Fail Delay’ duration. The failure can be a CAN Too Slow or a CAN
No Signal depending on the number of messages received.
CanIn Fail Delay (sec)
CAN demand signal failure delay in seconds.
default = 0.3 sec (0.1 to 10)
This transient current limit and steady state currents are both actively trying to
position the output prior to either min or max stop current limit activation—that is,
prior to this limit engagement the current may reach the transient limit followed by
the steady state limit.
These settings provide integration limits only on the current controller, so the
actual current can exceed this setting. The current error above this setting is
proportional to the demand-to-position error. If the demand continues to increase
(or decrease) once the max (or min) limit is reached, the current will also
increase proportionally. The transient and steady-state current limits are still
active – the current will not exceed these limits.
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Demand Track Error (%)
default = 15 % (1.0 to 100)
Tracking error adjustment for the demand inputs when using redundant demand
inputs (both primary and backup). This setting is the maximum difference
between the controlling demand and the standby demand in percentage before a
tracking alarm will be issued. The difference must exceed the ‘Error’ percentage
value for the ‘Error Delay’ duration to generate an alarm. A value of ‘100’ will
disable the alarm.
Demand Track Error Delay (sec)
default = 1 sec (0.1 to 10)
Tracking error delay in seconds—see Demand Tracking Error.
Position Error Max (%)
default = 10 % ( 1.0 to 110)
This setting is the maximum difference between the position demand and the
actual position in percentage before a position error alarm will be issued. The
difference must exceed the ‘Error’ percentage value for the ‘Error Delay’ duration
to generate an alarm. Note that there is some filtering done internally to model
the expected actuator response and minimize nuisance alarms. This setting
applies to any Demand source, primary or backup.
Note: The position demand is limited internally between 0 and 100, for position
error detection only, to eliminate false position error alarms.
Position Error Delay (sec)
default = 1 sec ( 0.1 to 10)
Position error delay in seconds—see Position Error Max.
PwmIn Fail Min Freq (%)
default= 85 % of nominal freq (50 to 99)
Value at which the PWM input will be determined as failed. The setting is
expressed as a percentage of the nominal frequency set in the Configure Mode
(i.e. 85 % of a nominal of 1000 Hz would equate to a fail level of 850 Hz). A
failure is determined if the PWM input frequency is below the ‘Fail Min’ hertz level
for the ‘PwmIn Fail Delay’ time.
PwmIn Fail Max Freq (%)
default= 115 % of nominal freq (101 to 150)
Value at which the PWM input will be determined as failed. The setting is
expressed as a percentage of the nominal frequency set in the Configure Mode.
A failure is determined if the PWM input frequency is above the ‘Fail Max’ hertz
level for the ‘PwmIn Fail Delay’ time.
PwmIn Fail Min Duty (%)
default= 5 % (1 to 50)
Duty cycle value at which the PWM input will be determined as failed. A failure is
determined if the PWM input duty cycle is below the ‘Fail Min’ duty cycle level for
the ‘PwmIn Fail Delay’ time.
PwmIn Fail Max Duty (%)
default= 95 % (50 to 99)
Duty cycle value at which the PWM input will be determined as failed. A failure is
determined if the PWM input duty cycle is above the ‘Fail Max’ duty cycle level
for the ‘PwmIn Fail Delay’ time.
PwmIn Fail Delay (sec)
PWM input failure delay in seconds.
PwmIn Filter
Lag-tau filter adjustment on the PWM input.
80
default = 0.1 sec (0.01 to 10)
default = 0.01 (0 to 1)
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Stops—Min Stop Bias (deg)
default = 0.5 degrees (–10 to 10)
Electrical Stop adjustment in degrees of rotation. This is an actuator range
adjustment setting for an extra “bias” when at the minimum output position. This
value biases the overall 0 % demand position. When positive, this setting can
help prevent the ProAct control's current driver from driving the actuator into the
hard stops (mechanical limits) when the stop is reached by effectively moving the
minimum stop position further from the mechanical stops (see also the Current
Limit – Min Stop on the Service Hardware Adjustments tab sheet). Setting this
parameter to a negative value will force the output current to drive into the
mechanical stop harder to ensure the valve is closed. Refer also to the Adjust
User Stops section in the Service Mode.
Stops—Max Stop Bias (deg)
default = 0.5 degrees (–10 to 10)
Electrical Stop adjustment in degrees of rotation. This is an actuator range
adjustment setting for an extra “bias” when at the maximum output position. This
value biases the overall 100 % demand position. When positive, this setting can
help prevent the ProAct control's current driver from driving the actuator into the
hard stops (mechanical limits) when the stop is reached by effectively moving the
minimum stop position further from the mechanical stops (see also the Current
Limit – Max Stop on the Service Hardware Adjustments tab sheet). Setting this
parameter to a negative value will force the output current to drive into the
mechanical stop harder to ensure the valve is opened. Refer also to the Adjust
User Stops section in the Service Mode.
Monitoring Application Parameters
All pertinent control parameters can be monitored in the Service mode. There are
tab sheets for Unit Status information, Position Control information, Alarm status,
Shutdown status, Error Log, and Temperature Histogram.
Service: Unit Status
The Unit Status tab sheet contains general actuator status information.
Figure 9-11. Service Mode: Unit Status
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Mode String—Indication of the current active “mode” of the actuator. Can any
one of the following:
1 Initialize
2 Check Mode
3 Shutdown
4 Running
5 Configure
6 Test Mode
7 Feedback Sens/Power Fail
8 Low Power Standby Mode
9 Factory Calib
10 User Calibration Mode
11 EEPROM Error
Mode Int—Integer indication of the mode string (see above).
ProAct Software Version—Displays the version number of the software
installed.
Config ID—Displays the identification of the software system configurables. The
default for this parameter is ProAct Digital Plus Configuration, however this string
can be edited in the CFG file to a more meaningful name relative to the specific
application setup and then downloaded back into the ProAct control.
CAN ProAct Number—Indication of the identification number used in the CAN
communication. Based on the status of the CAN ID Hi and Lo discrete inputs at
power-up.
Elect Temp (°C)—Indication of the detected electronics temperature in degrees
Celsius.
RunTime–Clear Command—Command to clear the accumulated RunTime.
RunTime–Hours—Accumulated runtime hours since the last Run Time Clear
command was issued. Time accumulates whenever the unit is powered up and is
stored on an hourly basis or if the Low Power Standby Mode discrete input is
enabled.
RunTime–100mSec—Accumulated runtime in units of 100 ms (36 000 in an
hour). Resets to zero on a power-up or Clear command. Time accumulates
whenever the unit is powered-up and is stored on an hourly basis or if the Low
Power Standby Mode discrete input is enabled.
Shutdown Command—Command to force the unit into a shutdown condition
using the Service Tool. Helpful for entering into modes that require the unit to be
shut down, like Configure or Adjust User Stops. This command can be toggled
between true and false. When toggled to true, the unit remains in a shutdown
state until this parameter is set back to false or the power is cycled on the
ProAct.
Status–Alarm—General indication that an alarm condition exists, refer to the
Status Error—Alarms tab sheet for the specific alarm condition.
Status–Shutdown—General indication that a Shutdown condition exists, refer to
the Status Error—Shutdowns tab sheet for the specific condition.
Status–Low Pwr Stdby—General indication that the unit is in Low Power Standby
Mode, refer to the Status Error—Shutdowns tab sheet for the specific condition.
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Service: Position Control
The Position Control tab sheet contains position control information.
Figure 9-12. Service Mode: Position Control
Position Demand (%)—Indication of the actual position demand signal, based
on unit configuration, in percentage of the user calibrated range.
Actual Posn (%)—Indication of the actual driver shaft output position, in
percentage of the user calibrated range.
Actual Posn (deg)—Indication of the actual driver shaft output position, in
degrees rotation, relative to absolute shaft position. For models I through IV, full
counterclockwise is zero degrees and full clockwise is 75 degrees.
Actual Current (A)—Indication of the actual current, in amps, from the driver to
the actuator.
Position Demand Error (%)—Indication of the difference between the demand
position and the actual position in percentage of the user calibrated range. This
error is filtered based on the internal model to prevent inadvertent alarm
indications (see position error alarm).
Primary Demand (%)—Indication of the primary position demand signal, based
on unit configuration, in percentage of the user calibrated range. If the primary
demand signal is failed, this parameter stops updating.
Backup Demand (%)—Indication of the backup position demand signal, based
on unit configuration, in percentage of the user calibrated range. If the backup
demand signal is failed, this parameter stops updating.
Primary Control–Control Indication—True if the primary demand is the
selected demand signal.
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Primary Fault—Indication of the primary demand signal status. True indicates a
failed value. This indication does not include a tracking error. The position
demand will not transfer from the backup to the primary if a demand tracking
error exists.
Backup Control–Control Indication—true if the backup demand is the selected
demand signal. Unit will remain in backup control if the primary signal fails and
transfers back to primary when the signal is restored and within the tracking error
(see Service: Hardware Adjustments).
Backup Fault—Indication of the backup demand signal status. True is failed and
false if not. This indication does not include a tracking error.
Demand–Analog Demand (%)—Continuously updated indication, even when
failed, of the analog input position demand signal in percentage of the user
calibrated range.
Demand–Can Demand (%)—Continuously updated indication, even when failed,
of the CAN position demand signal in percentage of the user calibrated range.
Demand–PWM Demand (%)—Continuously updated indication, even when
failed, of the PWM input position demand signal in percentage of the user
calibrated range.
Xfer to Backup—When set to true, this user command forces the demand signal
from primary to the configured backup signal. The force is not performed if the
backup demand is failed or if the ‘Xfer to Primary’ command is true. Used to test
primary/backup transfers and to facilitate the code required with the addition of
daughter board commands.
Xfer to Primary—User command to transfer control from backup to the
configured primary signal (if it’s not failed). Normally this would happen
automatically if the primary is properly tracking. This command forces transfer to
primary even though it may not be tracking the backup within tolerances set in
the Service mode. This command overrides the ‘Xfer to Backup’ command by
transferring the demand to primary control and setting ‘Xfer to Backup’ to false.
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Service: Status Errors—Alarms
The Status Errors—Alarms tab sheet contains status information on all monitored
actuator alarms. Values that are TRUE, indicate the alarm condition is active.
The Alarm indication is non-latching and returns to false when the condition no
longer exists. Refer to the Alarm diagnostics in Chapter 6 for details.
Figure 9-13. Service Mode: Status Error Alarms
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Service: Status Errors—Shutdowns
The Status Errors—Shutdowns tab sheet contains status information on all
monitored actuator shutdowns. Values that are TRUE, indicate the shutdown
condition is active—forcing the unit from normal (running) operation into a
shutdown mode. The Shutdown indication is non-latching and returns to false
when the condition no longer exists. Refer to the Shutdown diagnostics in
Chapter 6 for details.
Figure 9-14. Service Mode: Status Error Shutdowns
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Service: Status Errors—Log
The Status Errors—Log tab sheet contains the logged status history information.
The ErrorLog displays the shutdown and alarm events that occurred since the
last “clear” command. It displays the event number, the relative time of the first
occurrence, and the number of times this event has been detected. The Error
Log changes are saved into non-volatile memory every 100 ms.
Figure 9-15. Service Mode: Status Error Log (1)
Clear ErrorLog—Command to clear the error log of all errors. When issued, all
Codes, Counters, and Times are set to zero. When a Clear Error Log is selected,
the reset time changes to the present runtime hours (displayed under Unit
Status). Errors that exist at the time of the reset are not re-logged, only newly
triggered events.
Last Alarm—Event code indication of the last alarm condition.
Last Shutdown—Event code indication of the last shutdown condition.
ErrorLog Reset Time—Time, relative to the Run Time (See Unit Status tab
sheet), of the last ‘Clear ErrorLog’ command.
Entryxx ErrorCode—Integer indication of the detected alarm or shutdown event.
The integer corresponds to the number in parentheses listed in the Alarm or
Shutdown text, for example ‘PWM No Signal (53)’ is code 53.
Entryxx Counter—Number of times the entry has been detected since the last
time the log was cleared.
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Entryxx Time—Time of the first detected occurrence, in hours, relative to how
long the unit was running since the last time the log was cleared. The recorded
time is based on difference between the RunTime Hours (found under the Unit
Status tab sheet) and the ErrorLog Reset Time. For example, if a fault occurs
and this is the first occurrence of this fault, the logged time would be 431—
assuming RunTime Hours=641 and ErrorLog Reset Time=210. Another example,
if the Entryxx Time was 55 and the Reset Time was 200, the time of occurrence
was during RunTime hour 255.
If the RunTime is cleared, the runtime is reset to zero. If the run time is less than
the reset time, the time in the log will be zero until the runtime exceeds to reset
time.
Figure 9-16. Service Mode: Status Error Log (2)
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Service: Temp Histogram
The Temp Histogram tab sheet contains the temperature histogram. The
temperature histogram provides a historical indication of the electronic
temperatures of the unit. The parameter value indicates the number of seconds
the unit was within the indicated temperature band. For example, the Field ‘8
70°C’ records the accumulated time the temperature was between 70 and 80 °C.
The temperature histogram is saved hourly in EEPROM or if the Low Power
Standby Mode discrete input is enabled, and is only cleared if a new software
program is downloaded into the unit.
Figure 9-17. Service Mode: Temperature Histogram
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Chapter 10.
Troubleshooting
Introduction
Improper engine operation is often the result of factors other than governor
operation. This chapter gives tips about engine problems, which can resemble
governor problems. Make sure the engine is operating correctly before making
any changes in the governor. The following troubleshooting guide is an aid in
isolating trouble to the control box, actuator, wiring, or elsewhere.
Troubleshooting beyond this level is recommended ONLY when a complete
facility for control testing is available.
Attempting to correct engine or load problems with untimely governor adjustment
can make problems worse. If possible, isolate the governor from the engine to
determine if the problem is with the governor and not with the engine or the load
on the engine. Governor faults are usually caused by problems in the installation
or the linkage between the actuator and the engine.
Carefully review all the wiring connections, the power supply, and the linkage
before making any adjustments to the actuator or driver. Always check the fuelcontrol linkage from stop to stop as if the actuator were moving it. The linkage
must move freely without friction and without backlash. Some fuel controls will
present problems at particular fuel or rack positions because of a hesitation or
binding in the linkage.
Fuel supply and injector conditions can also present problems, which resemble
governor problems. On spark-ignited engines, distributor, coil, points, and timing
problems can all cause improper operations, which may resemble faulty governor
control.
The control can be damaged with the wrong voltage. When replacing
a control, check the power supply, battery, etc., for the correct
voltage.
Troubleshooting Procedure
This chapter is a general guide for isolating system problems. The guide
assumes that the system wiring, soldering connections, switch and relay
contacts, and input and output connections are correct and in good working
order. Make the checks in the order indicated. Various system checks assume
that the prior checks have been properly done.
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General System Troubleshooting Guide
The following is a general troubleshooting guide for areas to check which may
present potential difficulties. By making these checks appropriate to your
engine/turbine before contacting Woodward for technical assistance, your system
problems can be more quickly and accurately assessed.
Actuators
Is the actuator wiring correct?
Is the direction of the stroke correct? (This is configured using the Service Tool.)
Has the feedback signal been calibrated? (This is calibrated through the Service
Tool.)
Had Load Inertia been set? (This is set using the Service Tool.)
Linkage
Is there slop or lost motion?
Is there misalignment, binding, or side loading?
Is there visible wear or scarring?
Does the linkage move smoothly?
Valves
Does the valve move through its proper stroke smoothly?
Does the valve travel its full stroke?
Can mid-stroke be obtained and held?
Does the valve fully seat (close) before the governor reaches full minimum
stroke?
Does the valve fully open before the governor reaches maximum stroke?
Mechanical Troubleshooting Guide
Linkage and Actuator Stroke
Use as much of the 75 degrees of actuator stroke as possible. Carefully follow
the guidelines in the Driver Adjustments section of Chapter 2 in making linkage
arrangements. Using less than optimum actuator movement will make stability
more difficult, and will make the actuator more sensitive to external loading
forces and friction.
Actuator exhibits “hunt” or large limit cycle.
Check for loose terminal lever.
Check for loose or worn linkage.
Verify correct mounting hardware.
Verify mounting bolts are tightened to appropriate torque values.
Verify inertia setting.
Unable to rotate stand alone actuator in unpowered condition
Internal mechanical failure—replace actuator.
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Electrical Troubleshooting Guide
Analog Input
If the Analog input is not functioning properly, verify the following:

Measure the input voltage on the terminal block. It should be in the range of
(0 to 5) V.

Verify that there are no or minimal ac components to the Analog Input
signal. AC components can be caused by improper shielding.

Check the wiring. If the inputs are reading 0 or the engineering units that
correspond to 0 mA, look for a loose connection at the terminal blocks and
disconnected or misconnected cables. Check for proper jumper installation
on the terminal block (JPR1 for 200 mA range and JPR2 for 20 mA range).

Check for proper jumper installation on the terminal block (JPR1 for 200 mA
range and JPR2 for 20 mA range).

If all of the inputs are reading high, check that the power is not connected
across the input directly.

Check the software configuration to ensure that the input is configured
properly as either a primary or backup demand. Verify the Analog In Min
and Max Value configurations.

Check the values seen by the ProAct actuator using the Service Tool in the
Service mode under Position Control, Analog Demand. If the input is failed,
as indicated by flash code 51, and the milliamp input is in the normal range,
check the Service mode settings for Analog In Fail Min and Fail Max.
Analog Output
If the Analog output is not functioning properly, verify the following:

Check the load resistance, ensure that it is less than the specification limit
for the output current.

Check to ensure that the load wiring is isolated.

Check the wiring, look for a loose connection at the terminal blocks and
disconnected or misconnected cables.

Disconnect the field wiring and connect a resistor across the output. If the
output is correct across the resistor, there is a problem with the field wiring.

If Watch Window Professional is available, the output current can be forced
from the Test Mode to verify functionality. In addition, Offset and Gain
adjustment are available in the Service Mode.
Discrete Inputs
If a discrete input is not functioning properly, verify the following:

Measure the input voltage on the terminal block. It should be in the range of
(18 to 28) V (dc).

Check the wiring, look for a loose connection at the terminal blocks and
disconnected or misconnected cables.
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Alarm or Shutdown Conditions
If the ProAct actuator has any alarm or shutdown conditions, refer to Chapter 6
for details on the exact cause of the condition. The LED will indicate a flash code
for shutdown conditions. Watch Window or CAN must be used to determine any
alarm conditions.
Discrete Output
If the discrete output is not functioning properly, verify the following:

Measure the output voltage on the terminal block. It should be in the range
of (18 to 28) V (dc) when the output is off/false. The voltage will be in this
range only if all alarms and shutdowns are false. This can be verified
through Watch Window . The output protection circuit will remove this
voltage if the output was shorted to ground. This requires a power cycle
(off/on) to restore the output once the problem is corrected.

Check the wiring, look for a loose connection at the terminal blocks and
disconnected or misconnected cables.

If Watch Window Professional is available, the output can be forced on and
off from the Test Mode to verify functionality.
Serial (RS-232) Communications
If a serial port is not functioning properly, verify the following:

Check the wiring, look for a loose connection and disconnected or
misconnected cables.

Check the communication settings, should be set to 19200 baud, 8 data
bits, 1 stop bit, and no parity.
Service Tool
If a serial port is not functioning properly, review the installation information in
Chapter 8. Verify the following:

Check the wiring, look for a loose connection and disconnected or
misconnected cables. Refer to the Serial (RS-232) Communications
troubleshooting above.

Check that Servlink is running and communicating with the control. Check
that Watch Window is running. Verify the Servlink Error settings. If numbers
don’t appear to be displayed correctly, verify the proper numeric format
setting. Refer to Chapter 8 (Service Tool) for details.
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CAN Communications
If a CAN port is not functioning properly, verify the following:

Check the wiring, look for a loose connection at the terminal blocks and
disconnected or misconnected cables. Check wiring of termination resistor,
if required.

Check the configured data rate (250, 500, 1000 kbps) in both the ProAct
Service Tool and the speed control.

Verify the appropriate Extension Set is configured.

Verify the appropriate Device address is utilized. Check the CAN ID discrete
inputs—they are only monitored during a power up, so ProAct power may
need to be cycled. This parameter can also be verified using the Service
Tool and monitor the Service Mode CAN ProAct Number under the Unit
Status tab sheet.

If mis-wired, the CAN driver chip can fail. This could occur when the CAN Hi
or Lo connections are inadvertently wired to 30V or more. This failure
requires a factory replacement of the CAN driver chip.
Performance Troubleshooting Guide
General Performance Problems


Verify appropriate Inertia Number is set. Try increasing and testing Inertia
Setting to improve performance—refer to the Service Mode: Adjust User
Stops tab sheet.
If Watch Window Professional is available, run the actuator with an internally
generated demand (test mode 2) to check for demand signal problems.
If the actuator buzzes, or has a fast limit cycle:

Set “High Friction Load” = False, found on the Service Mode: Adjust User
Stops tab sheet.

Decrease the Actuator Inertia Setting and re-run the Inertia Test (Service
Mode: Adjust User Stops tab sheet).

Check for loose linkage.
If the actuator overshoots on steps, or is poorly damped:

Increase the Actuator Inertia Setting and re-run the Inertia Test (Service
Mode: Adjust User Stops tab sheet).
If the actuator has a slow limit cycle:

Set “High Friction Load” = True, found on the Service Mode: Adjust User
Stops tab sheet.

Increase the Actuator Inertia Setting and re-run the Inertia Test (Service
Mode: Adjust User Stops tab sheet).

Free stuck linkage or load.
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Actuator has steady state position error:

Re-run stop position calibration (Service Mode: Adjust User Stops tab
sheet).

Supply voltage too low.

Actuator load too large or actuator too small.

Free stuck linkage.

Actuator fault – replace actuator.
Actuator heats up when against stop:

Move electrical stops in from mechanical stops by increasing the ‘StopsMin/max Stop Bias’ settings found on the Service Mode: Hardware
Adjustments tab sheet.

De-power coil when at min stop.
Actuator has delay when moving off stop:

Move electrical stops in from mechanical stops by increasing the ‘StopsMin/max Stop Bias’ settings found on the Service Mode: Hardware
Adjustments tab sheet.

Increase load inertia and inertia setting.
Actuator maximum stop is inadvertently set lower than the actuator minimum
stop:

Must perform Adjusting User Stops in section 9 (recommend automatic
mode)
Woodward
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ProAct Digital Plus
Manual 26112
Chapter 11.
ProAct™ Digital Plus Specifications
Environmental Specifications
Acceptable Range or
Qualification Condition
(–40 to +85) °C. Under all conditions
the Temperature Monitoring Zone must
remain below 90 °C.
Specification Item
Operating
Temperature
Storage Temperature
Vibration
Comments
See Mechanical
Installation section of
manual for discussion
of this specification
item.
(–40 to +125) °C, unpowered.
Sine: 3.2 mm peak-to-peak for 2 Hz to
39.4 Hz, 10 G for 39.4 Hz to 300 Hz.
Random: 0.01 G²/Hz at 10 Hz, 0.10 at
100 Hz, 0.10 at 1000 Hz, 0.05 at 2000
Hz (12.79 Grms) 3 hours per axis.
MS1—40G 11ms sawtooth.
IP56 per IEC60529.
60 °C, 95 % RH for five days at one
cycle per day.
The ProAct Digital Plus uses materials
proven capable of withstanding normal
engine environment chemicals per
SAE J1455, such as diesel fuel, engine
oil, and antifreeze.
Shock
Ingress Protection
Humidity
Chemical Resistance
Hardware Specifications
Feature
Shaft
Mass Moment of Inertia
(lb-in-sec² / kgm²)
Minimum Steady State
Work Output
Minimum Transient Work
Output
Rotation
Weight
96
Specification
0.625-36 serrations.
Model I,II—4.9E-3 / 5.50E-4
Model III—5.6E-3 / 6.4E-4
Model IV—7.2E-3 / 8.1E-4
Model I—1.7 J (1.25 ft-lb)
Model II—3.4 J (2.5 ft-lb)
Model III—7 J (5 ft-lb)
Model IV—14 J (10 ft-lb)
Model I—3.4 J (2.5 ft-lb)
Model II—7 J (5 ft-lb)
Model III—14 J (10 ft-lb)
Model IV—27 J (20 ft-lb)
73–77°
Model I—11 kg (25 lb)
Model II—11 kg (25 lb)
Model III—15 kg (32 lb)
Model IV—24 kg (52 lb)
Comments
Woodward
Manual 26112
ProAct Digital Plus
Electrical Specifications
Feature
Input Power—max
Max Current—Transient
(internal current to the actuator
coil)
Specification
Model I—67 W (transient) / 19 W (continuous)
Model II—251 W (transient) / 65 W (continuous)
Model III—282 W (transient) / 73 W (continuous)
Model IV—371 W (transient) / 101 W (continuous)
Model I—13 A (transient) / 7 A (steady state)
Model II—13 A (transient) / 7 A (steady state)
Model III—20.6 A (transient) / 11.3 A (steady state)
Model IV—20.6 A (transient) / 11.3 A (steady state)
I/O Specifications
Analog Input
Input type:
Max input current (full scale):
Common mode rejection:
Input common mode range:
Safe input common mode volt:
Input impedance:
Anti-aliasing filter:
Resolution:
Accuracy:
Temp Drift:
I/O Latency:
Fault Detection:
PWM Command Input
Input Magnitude:
Frequency Range:
Isolation:
Input common mode range:
Safe input common mode volt:
Input Impedance:
Input type:
Resolution:
Accuracy:
Temperature drift:
I/O Latency:
Fault Detection:
(4 to 20) mA or (0 to 200) mA, jumper selectable,
balanced differential input
25 mA ± 2 % (20 mA range)
225 mA ± 2 % (200 mA range)
–60 dB minimum
±50 V minimum
±200 V minimum
225  (±10 %) (20 mA range)
25  (±10 %) (200 mA range)
2 anti-aliasing poles at 1 ms (159 Hz)
12 bits (using Gaussian Noise)
±1.5 % of full scale, @ 25 °C
300 ppm/°C, maximum (1 % of full scale)
2 ms
Service Mode software setting
(7 to 32) V balanced differential input
(100 to 3000) Hz
none
±50 V minimum
±50 V minimum
40 k
Single ended, ground referenced input
12 bits
±1.5 % of full scale, @ 25 °C
300 ppm/°C
2 ms
Service Mode software settings for both
Frequency and Duty Cycle
Analog Output
Output Type:
PWM frequency:
Current output:
Max current output:
Output common mode voltage:
Min. load resistance:
Max. load resistance:
Resolution:
Accuracy:
Temperature Drift:
I/O Latency:
Woodward
(4 to 20) mA, non-isolated, high side driver output
6 kHz
(4 to 20) mA
25 mA ± 5 %
24 V (dc)
0
335  at 22 mA with base power supply
10 bits
±1.5 % of full scale at 25 °C
250 ppm/°C, maximum
10 ms
97
ProAct Digital Plus
Manual 26112
Discrete Inputs
Input type:
Input Thresholds:
Ground referenced discrete input
< 2 V (dc) = “ON”
> 7 V (dc) = “OFF”
1.2 mA @ 0 V (dc)
Referenced to battery negative
32 V (dc)
Input Current:
Contact Input:
Max Input Voltage:
Discrete Output
Output type:
Functionality:
Drive current:
Load range:
Protection:
High side discrete output driver
Status indicator, output will energize on failure
500 mA, max (with a 48  load)
48  to 100 k
Short circuit protection will remove output power,
when activated, and requires a power cycle to
clear
CAN Communication
Type:
Protocol:
2-wire CAN, version 2.0B, with 29-bit identifiers
Complies with SAE J1939, but uses proprietary
group extensions
250 kbps, 500 kbps and 1 Mbps
Jumper selectable termination resistor (125 )
Configurable data rate of:
CAN termination:
Bus length:
Maximum Length
Data Rate (bps)
meters (feet)
250 k
250 (820)
500 k
100 (328)
1M
40 (131)
Service Mode software settings
Fault Detection:
RS-232 Serial Communication Service Port
Isolation:
None
Baud Rate:
Fixed 19.2 Kbaud
Mechanical Interface:
9-pin sub-D male connector
Pinout:
Tx = pin 2, Rx = pin 3, Gnd = pin 5
Maximum Cable Length:
15 m (50 ft)
Electronics Temperature Sensor
Accuracy:
±1 °C at 25 °C ambient
±2 °C over full range (–40 to +125 °C)
I/O Latency:
100 ms
Current Feedback Sensing
Input:
Circuit Output:
Software Output:
Accuracy:
Temperature Drift:
I/O Latency:
±29.9 A
(0 to 5) V (dc) to analog-to-digital converter
±29.9 A reading
±1.5 % of full scale at 25 °C
400 ppm/°C, maximum
1ms
Actuator
Model
Coil
Resistance @
22 °C (ohms)
Coil Inductance
@ 5 Hz (mH)
Steady State
Current to
Coil (amps)
Transient
Current to Coil
(amps)
I
II
III
IV
0.254
1.02
0.420
0.600
10
42
26
50
6
6
10
10
12
12
20
20
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Woodward
Manual 26112
ProAct Digital Plus
Position Feedback Sensing
Input:
Circuit Output:
Software Output:
Positioning Repeatability:
Positioning Linearity:
Positioning Accuracy:
Temperature Drift:
I/O Latency:
~(1 to 4) V (dc) from Hall-Effect Sensor
~(0.5 to 4.5) V (dc) to analog-to-digital converter
0–75 degrees (1.31 radians) rotation (software
assumes 75 degrees travel)
<±1 % of full stroke at 25 °C after calibration
<±1.5 % of full stroke at 25 °C after calibration
<±1.0 % of full stroke at 25 °C after calibration
and ±1.5 % linearity
<±350 ppm/°C, maximum after calibration
1ms
Software
Microprocessor:
Execution Rates:
Motorola 68376 Microcontroller 20 MHz
Software Routine
Position and Current Control Algorithms
Analog Output
Position Demand Algorithms
Analog Input Logic
PWM Input Logic
CAN Demand Signal
CAN Transmissions
Temperature Sensing and current limiting
Temperature Histogram
Serial Port
LED
Discrete Inputs:
Run Enable (Low Power Standby Mode)
Can ID Lo and Hi
Jumper Input (4 mA to 20 mA/20 mA to 180 mA)
Discrete Output
Diagnostics:
Current and Position sensor faults
Demand signal faults*
Position Error
Low Power Standby Mode
A/D Converter error
Voltage Errors
Watchdog Timeout
Tracking Fault
CAN Faults
Temperature Faults
RS-232 (Servlink) Shutdown
Nominal Software
Execution Rate
1 ms
10 ms
2 ms
2 ms
2 ms
2 ms
100 ms
100 ms
1s
background task
background task
5 ms
only on power up
only on power up
1 ms
1 ms
2 ms
10 ms
10 ms
100 ms
100 ms
100 ms
100 ms
100 ms
100 ms
background task
* Execution of PWM input faults varies with the sampling frequency of the PWM input. The sampling
frequency is based on the lowest detectable frequency and is defined as the (Nominal Freq*Fail Min
Freq*0.8).
PWM Sampling Freq (Hz) Fault Execution Rate (ms)
501+
2
251-500 4
126-250 8
63-125
16
31-62
32
15-30
64
Woodward
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ProAct Digital Plus
Manual 26112
Performance
Parameter
Bandwidth
Specification
(measured at -6 db) > second order, 40 rad/s
–3 db at >8 Hz with low inertia. See ProAct Transfer
Function
> 1000 degrees/second
>18.5 rad/s (10 % to 90 % travel)
< 0.25 degrees peak to peak with low friction loads
<0.1 degree for loads up to 80 % of steady state current
limit.
Integrating control drives steady state error to zero.
Adjusts to work with 450:1 range of (actuator + load) inertia.
0
Max Slew Rate
Limit Cycle
Steady State Error
Inertia Range
Min Load Inertia
Transfer Function
The ProAct transfer function is nominally a rate limit followed by three lags. The
rate limit varies with actuator model, and the lags are scheduled with actuator
model and inertia (see table, below).
1
1
1
(T au1)s+1
(T au2)s+1
(T au3)s+1
1
Dem and
Rate Lim iter
1
Position
Figure 11-1. Transfer Function
Inertia Number Setting
ProAct I & II ProAct III
> 21
> 23
18 – 21
20 – 22
15 – 17
17 – 19
9 – 14
12 – 15
6–8
9 – 11
3–6
6–8
<3
<6
ProAct IV
> 22
19 – 21
16 – 19
11 – 15
8 – 10
5–7
<5
Time Constants [seconds]
Tau 1
Tau 2
0.0333
0.0222
0.0286
0.0182
0.0222
0.0167
0.0200
0.0111
0.0167
0.0083
0.0133
0.0071
0.0118
0.0071
Tau 3
0.0077
0.0100
0.0100
0.0083
0.0071
0.0063
0.0063
Table 11-1. Transfer Function Parameters
Rate Limiter Values:
ProAct I:
ProAct II:
ProAct III:
ProAct IV:
3750 deg/sec
1923 deg/sec
1595 deg/sec
797 deg/sec
Inertia Settings
Inertia=Base_Inertia*1.25^InertiaNumber
The actuator with no load has inertia = Base_Inertia
ProAct Size
ProAct I
ProAct II
ProAct III
ProAct IV
100
Base_Inertia
4.3e-4 kgm^2 (or N-m-sec^2)
4.3e-4 kgm^2
5.1e-4 kgm^2
6.5e-4 kgm^2
Woodward
Manual 26112
ProAct Digital Plus
Chapter 12.
Product Support and Service Options
Product Support Options
If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
1. Consult the troubleshooting guide in the manual.
2. Contact the OE Manufacturer or Packager of your system.
3. Contact the Woodward Business Partner serving your area.
4. Contact Woodward technical assistance via email
(EngineHelpDesk@Woodward.com) with detailed information on the
product, application, and symptoms. Your email will be forwarded to an
appropriate expert on the product and application to respond by telephone
or return email.
5. If the issue cannot be resolved, you can select a further course of action to
pursue based on the available services listed in this chapter.
OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.
Woodward Business Partner Support: Woodward works with and supports a
global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:

A Full-Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.

An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on
Woodward's behalf. Service (not new unit sales) is an AISF's primary
mission.

A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.
A current list of Woodward Business Partners is available at
www.woodward.com/directory.
Product Service Options
Depending on the type of product, the following options for servicing Woodward
products may be available through your local Full-Service Distributor or the OEM
or Packager of the equipment system.

Replacement/Exchange (24-hour service)

Flat Rate Repair

Flat Rate Remanufacture
Woodward
101
ProAct Digital Plus
Manual 26112
Replacement/Exchange: Replacement/Exchange is a premium program
designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.
This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.
Flat Rate Repair: Flat Rate Repair is available for many of the standard
mechanical products and some of the electronic products in the field. This
program offers you repair service for your products with the advantage of
knowing in advance what the cost will be.
Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option, with the exception that the unit will be returned to you in “likenew” condition. This option is applicable to mechanical products only.
Returning Equipment for Repair
If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.
When shipping the item(s), attach a tag with the following information:

return number;

name and location where the control is installed;

name and phone number of contact person;

complete Woodward part number(s) and serial number(s);

description of the problem;

instructions describing the desired type of repair.
Packing a Control
Use the following materials when returning a complete control:

protective caps on any connectors;

antistatic protective bags on all electronic modules;

packing materials that will not damage the surface of the unit;

at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;

a packing carton with double walls;

a strong tape around the outside of the carton for increased strength.
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.
Replacement Parts
When ordering replacement parts for controls, include the following information:

the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;

the unit serial number, which is also on the nameplate.
102
Woodward
Manual 26112
ProAct Digital Plus
Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our
products. For these services, you can contact the Distributor by telephone or by
email.

Technical Support

Product Training

Field Service
Technical Support is available from your equipment system supplier, your local
Full-Service Distributor, or from many of Woodward’s worldwide locations,
depending upon the product and application. This service can assist you with
technical questions or problem solving during the normal business hours of the
Woodward location you contact.
Product Training is available as standard classes at many Distributor locations.
Customized classes are also available, which can be tailored to your needs and
held at one of our Distributor locations or at your site. This training, conducted by
experienced personnel, will assure that you will be able to maintain system
reliability and availability.
Field Service engineering on-site support is available, depending on the product
and location, from one of our Full-Service Distributors. The field engineers are
experienced both on Woodward products as well as on much of the nonWoodward equipment with which our products interface.
For information on these services, please contact one of the Full-Service
Distributors listed at www.woodward.com/directory.
Contacting Woodward’s Support Organization
For the name of your nearest Woodward Full-Service Distributor or service
facility, please consult our worldwide directory published at
www.woodward.com/directory.
You can also contact the Woodward Customer Service Department at one of the
following Woodward facilities to obtain the address and phone number of the
nearest facility at which you can obtain information and service.
Products Used In
Electrical Power Systems
Products Used In
Engine Systems
Products Used In
Industrial Turbomachinery
Systems
Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727
Germany:
Kempen ---- +49 (0) 21 52 14 51
Stuttgart-- +49 (711) 78954-510
India --------------- +91 (129) 4097100
Japan -------------- +81 (43) 213-2191
Korea -------------- +82 (51) 636-7080
Poland--------------- +48 12 295 13 00
United States ---- +1 (970) 482-5811
Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727
Germany------- +49 (711) 78954-510
India --------------- +91 (129) 4097100
Japan -------------- +81 (43) 213-2191
Korea -------------- +82 (51) 636-7080
The Netherlands - +31 (23) 5661111
United States ---- +1 (970) 482-5811
Facility---------------- Phone Number
Brazil ------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727
India --------------- +91 (129) 4097100
Japan -------------- +81 (43) 213-2191
Korea -------------- +82 (51) 636-7080
The Netherlands - +31 (23) 5661111
Poland--------------- +48 12 295 13 00
United States ---- +1 (970) 482-5811
For the most current product support and contact information, please visit our
website directory at www.woodward.com/directory.
Woodward
103
ProAct Digital Plus
Manual 26112
Technical Assistance
If you need to contact technical assistance, you will need to provide the following information.
Please write it down here before contacting the Engine OEM, the Packager, a Woodward
Business Partner, or the Woodward factory:
General
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information
Manufacturer
Engine Model Number
Number of Cylinders
Type of Fuel (gas, gaseous, diesel,
dual-fuel, etc.)
Power Output Rating
Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #2
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Control/Governor #3
Woodward Part Number & Rev. Letter
Control Description or Governor Type
Serial Number
Symptoms
Description
If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.
104
Woodward
Manual 26112
ProAct Digital Plus
Appendix.
ProAct™ Program Summary
APPLICATION ________________________________________________
ACTUATOR SERIAL NUMBER ____________________________________
For details on individual settings refer to chapter 9.
Configure Mode Settings
Service Mode Settings
Unit Setup tab sheet
Actuator
Actuator Type
= ______________
Actuator CCW Direction?
Yes ____ No ____
Actuator Inertia Setting
= ______________
High Friction System?
Yes ____ No ____
Discrete Out
Discrete Out Alarms Enabled?
Yes ____ No ____
Discrete Out Includes Runenable? Yes ____ No ____
Shutdown
Shutdown Action
= ______________
Temp Limit
Temp Protect Enable?
Yes ____ No ____
Temp Alarm SP (°C)
= ______________
Temp Alarm Delay (sec)
= ______________
Hardware Adjustments tab sheet
Analog In
AnalogIn Fail Delay (sec)
= ______________
AnalogIn Filter
= ______________
AnalogIn 20 Fail Min (mA)
= ______________
AnalogIn 20 Fail Max (mA)
= ______________
AnalogIn 200 Fail Min (mA)
= ______________
AnalogIn 200 Fail Max (mA)
= ______________
PwmIn
PwmIn Fail Delay (sec)
= ______________
PwmIn Filter
= ______________
PwmIn Fail Min Freq (%)
= ______________
PwmIn Fail Max Freq (%)
= ______________
PwmIn Fail Min Duty (%)
= ______________
PwmIn Fail Max Duty (%)
= ______________
Demand
Demand Track Error (%)
= ______________
Demand Track Error Delay (sec) = ______________
Position Control
Position Error Max (%)
= ______________
Position Error Delay (sec)
= ______________
Analog Out
Analog Out Offset (mA)
= ______________
Analog Out Gain
= ______________
Stops
Stops—Min Stop Bias (deg)
= ______________
Stops—Max Stop Bias (deg)
= ______________
CAN
CanIn Fail Delay (sec)
= ______________
CanIn Min (msg/s)
= ______________
Demand Setup tab sheet
Demand
Demand – Primary Source
Demand – Backup Source
Analog In
AnlgIn 20 Min Value (mA)
AnlgIn 20 Max Value (mA)
AnlgIn 200 Min Value (mA)
AnlgIn 200 Max Value (mA)
PwmIn
PwmIn Min Duty (%)
PwmIn Max Duty (%)
PwmIn Frequency (Hz)
PwmIn Invert Input Signal?
CAN
CAN Extensions
CAN Data Rate
Woodward
= ______________
= ______________
= ______________
= ______________
= ______________
= ______________
= ______________
= ______________
= ______________
Yes ____ No ____
= ______________
= ______________
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Manual 26112
ProAct Digital Plus
Service Tool Passwords
Documentation of the Service Tool passwords is provided here to allow
customers a single point of reference as well as a single page to remove for
security, if desired.
Mode
Configure Mode
Test Mode
Factory Calibration Mode
User Stops Mode
Woodward
Password
1113
1114
1115
1116
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108
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Manual 26112
ProAct Digital Plus
Summary of Alarms and Shutdowns
Servlink Variable
Code
Service:Status Error—Shutdowns
DI LowPwr Stdby (12)
12
RS232 Shutdown (13)
13
All Demands Failed (21)
21
A/D Converter Error (22)
22
Posn Sensor Failed (23)
23
Current Fdbk Failed (24)
24
Config Error (25)
25
Calibration Error (26)
26
Watchdog Timeout (27)
27
Service:Status Error—Alarms
Position ErrorAlert (31)
31
Primary Demand Fault (41)
41
Backup Demand Fault (42)
42
Tracking Error (43)
43
Analog Dmd Fault (51)
51
Pwm Freq Error (52)
52
Pwm Duty Error (53)
53
Pwm No Signal (54)
54
Can Bus Off Error (61)
61
Can Dmd No Signal (62)
62
Can Dmd Too Slow (63)
63
Hi Temp Alert (71)
71
Temp Limiting Active (72)
72
Temp Sensor Fault (73)
73
24V Supply Low (81)
81
24V Supply High (82)
82
Supply 12Volt Error (83)
83
Supply Neg9Volt Error (84)
84
Supply 5Volt Error (85)
85
Reference Voltage Error (86) 86
NonOperating Mode (91)
91
Software Error (92)
92
EEPROM Error (93)
93
Woodward
Flash
Auto Clear
12
13
21
22
23
24
25
26
27
yes
yes
yes
no
no
no
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
yes
no
no
109
ProAct Digital Plus
110
Manual 26112
Woodward
Revision History
Changes in Revision T—

Added NEMA 3R outdoor rating information to Regulatory Compliance
Changes in Revision R—

Updated Regulatory Compliance information

New Declaration of Conformity & Declaration of Incorporation
Declarations
We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
Please reference publication 26112T.
PO Box 1519, Fort Collins CO 80522-1519, USA
1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811  Fax +1 (970) 498-3058
Email and Website—www.woodward.com
Woodward has company-owned plants, subsidiaries, and branches,
as well as authorized distributors and other authorized service and sales facilities throughout the world.
Complete address / phone / fax / email information for all locations is available on our website.
2012/9/Colorado
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