Installation and Operation Manual: Proact™ Ii Electric Powered Actuator and Driver

Installation and Operation Manual
ProAct™ II Electric Powered

Actuator and Driver
Manual 04176D
WARNING
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.
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.
CAUTION
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.
Electronic controls contain static-sensitive parts. Observe the following

precautions to prevent damage to these parts.
• Discharge body static before handling the control (with power to the control
turned off, contact a grounded surface and maintain contact while handling the
control).
• Avoid all plastic, vinyl, and Styrofoam (except antistatic versions) around
printed circuit boards.
• Do not touch the components or conductors on a printed circuit board with
your hands or with conductive devices.
IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTION—indicates a potentially hazardous situation which, if not avoided, could

result in damage to equipment.
NOTE—provides other helpful information that does not fall under the warning or
caution categories.
Revisions—Text changes are indicated by a black line alongside the text.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© Woodward 1997
All Rights Reserved
Manual 04176 ProAct II Actuator/Driver
Contents
CHAPTER 1. GENERAL INFORMATION ........................................................... 1

Introduction.............................................................................................................1
CHAPTER 2. ELECTROSTATIC DISCHARGE AWARENESS ............................... 6
CHAPTER 3. INSTALLATION.......................................................................... 7
Unpacking...............................................................................................................7
Mounting .................................................................................................................7
Actuator Installation ................................................................................................7
Actuator Bracket .....................................................................................................9
Electrical Connections..........................................................................................10
Power Supply .......................................................................................................11
Position Feedback Adjustment.............................................................................13
Actuator Travel .....................................................................................................14
CHAPTER 4. DESCRIPTION OF OPERATION ................................................. 15
Electronic Circuits.................................................................................................15
Actuator Position Signal .......................................................................................16
Actuator ................................................................................................................16
CHAPTER 5. TROUBLESHOOTING ............................................................... 17
Linkage and Actuator Stroke ................................................................................17
CHAPTER 6. TECHNICAL SPECIFICATIONS .................................................. 18
Power Supply .......................................................................................................18
Actuator Position Feedback .................................................................................18
System Wiring ......................................................................................................18
Input Configurations .............................................................................................19
System Performance ............................................................................................19
CHAPTER 7. SERVICE OPTIONS ................................................................. 21
Product Service Options.......................................................................................21
Returning Equipment for Repair...........................................................................22
Replacement Parts ...............................................................................................23
How to Contact Woodward...................................................................................23
Engineering Services ...........................................................................................24
Technical Assistance............................................................................................25
PROACT™ II ACTUATOR/DRIVER SPECIFICATIONS..................................... 27
Woodward i
ProAct II Actuator/Driver Manual 04176
Illustrations and Tables
Figure 1-1. Outline Drawing of ProAct II Driver with IP56 Box...............................2

Figure 1-2. Outline Drawing of ProAct II Driver with Sheet Metal Box...................3
Figure 1-3. Outline Drawing of ProAct Actuator .....................................................4
Figure 1-4. Plant Wiring Diagram ...........................................................................5
Figure 3-1. Diesel Engine Travel Stops..................................................................9
Figure 3-2. Carburetor Travel Stops.......................................................................9
Figure 3-3. ProAct II Mounting Bracket ..................................................................9
Figure 3-4. Preparing Shielded Wiring .................................................................10
Figure 3-5. Correct Wiring to Power Supply.........................................................12
Figure 3-6. Incorrect Power Supply Wiring ..........................................................12
Figure 3-7. ProAct Driver Adjustment Locations ..................................................13
Figure 4-1. ProAct II Functional Block Diagram ...................................................15
ii Woodward
Chapter 1.
General Information
Introduction
The ProAct™ II driver converts either a 0–200 mA, 4–20 mA, 4–13 mA, 11–20
mA, PWM, or a 0–5 V control signal from a Woodward electronic control into a
specific actuator position. The driver provides a feedback of 0.5–4.5 V
corresponding to actuator position.
The ProAct II driver comes in two different package configurations: a sealed

aluminum box with conduit fittings for wiring, and a sheet metal box with
grommet holes for wiring. The sealed box is IP56 capable and is designed for
skid-mounted applications. The sheet metal box is designed for skid or control
box mounted applications in an additional enclosure for protection from the
elements. Both units have the same power supply requirements, vibration
capability, and system response.
The ProAct II drivers require a separate electrical supply of 20–32 Vdc. The
supply must be capable of providing a sustained 6 A and a peak 12 A for up to
two seconds for the driver.
The ProAct actuator provides up to 5.4 J (4.0 ft-lbs) transient and 2.7 J (2.0
ft-lbs) steady state of work to move the fuel-setting lever on the engine. The
actuators have position feedback.
Engine stability and response are set by the controlling device, not by the
actuator and driver. Follow the instructions for the controlling device while setting
up the engine control system.
The following configurations are available for the position command input.
Nominal Actuator Output for Woodward

Input Signal Input Range Input Range Package Configuration Part Number
5–32 volt 10% to 90% 0% to 100% actuator position IP56 box w/ 8400-016
1 kHz PWM duty cycle conduit connectors
push-pull source
0 to 200 mA 20 to 160 mA 0% to 100% actuator position IP56 box w/ 8400-011
conduit connectors
conduit connectors
conduit connectors
conduit connectors
0 to 5 Vdc 0.5 to 4.5 Vdc 0% to 100% actuator position IP56 box w/ 8400-017
conduit connectors
5–32 volt 10% to 90% 0% to 100% actuator position sheet metal enclosure 8400-021
1 kHz PWM duty cycle
push-pull source
0 to 200 mA 20 to 160 mA 0% to 100% actuator position sheet metal enclosure 8400-702
0 to 5 Vdc 0.5 to 4.5 Vdc 0% to 100% actuator position sheet metal enclosure 8400-022
Woodward 1
Figure 1-1. Outline Drawing of ProAct II Driver with IP56 Box
2 Woodward
Figure 1-2. Outline Drawing of ProAct II Driver with Sheet Metal Box
Woodward 3
Figure 1-3. Outline Drawing of ProAct Actuator
4 Woodward
Figure 1-4. Plant Wiring Diagram
Woodward 5
Chapter 2.
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.
CAUTION
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.
6 Woodward
Chapter 3.
Installation
Unpacking
Be careful when unpacking the electronic driver. Check the driver for signs of
damage, such as bent or dented panels, scratches, and loose or broken parts.
Notify the shipper and Woodward if damage is found.
Mounting
The driver box is designed to operate within an ambient temperature range of
–40 to +70 °C (–40 to +158 °F).
The driver is capable of withstanding the following vibration specifications:

Shock—US Mil Std 810C, M516.2, PL 40G, 11 ms sawtooth
Vibration—Random Vibration 0.04 G²/Hz WGC RV2
If the application has a higher vibration level than specified (0.04 G²/Hz),
vibration isolators must be used to keep the levels below the given levels.
Mount the driver in a location with space for adjustment and wiring access. Do
not expose the driver to sources of radiant heat such as exhaust manifolds or
turbochargers. Mount the driver close enough to the actuator and battery to meet
the wire length requirements (see wiring requirements in Chapter 6).
The driver will generate some heat, so surfaces must be open to normal air
movement. No special ventilation is required.
Ideally, the driver should be mounted flush to the metal side of a control cabinet,
protected from the weather and high humidity, and close to the engine being
controlled. Do not install the driver directly on the engine. The location should
provide protection from high-voltage or high-current devices, or devices which
produce electromagnetic interference. After initial adjustments are completed,
access to the driver will not be required for normal engine operation.
Actuator Installation
Thermal
The actuators are designed for installation on the engine. The actuators will
generate heat, especially when stalled or during other conditions requiring
maximum torque output. Maximum operating temperature for the ProAct II
actuator is 100 °C (212 °F).
The installer must consider the heat conductivity of the installation bracket, and
the operating temperature of the ultimate heat sink to which the bracket will be
attached. Generally the heat transfer abilities of aluminum and low-carbon steel
are better than those of high-carbon steel or stainless steel.
Woodward 7
Uninhibited air flow over the heat-exchanger fins on the side of the actuators will
help control possible heat problems. Keep the fins as clean as possible to
improve heat transfer. Do NOT paint the fins, since this will reduce the heat
transfer efficiency.
If operating temperature is a concern, contact Woodward for more information.
Fuel Position Stops

Diesel Stops. Diesel installations will generally use the fuel system minimum
and maximum position stops. Diesel engine racks are normally designed to
provide the minimum and maximum stops without binding.
The actuator's stops must not prevent the actuator from driving the fuel linkage to
the minimum and maximum positions. The linkage should be designed to use as
much actuator travel as possible, without preventing minimum and maximum fuel
positions (see Figure 3-1).
Gas Engine Stops. Butterfly valves in carburetors will often bind if rotated too far
toward minimum or maximum. For this reason, the stops in the actuator should
be used at both minimum and maximum positions. Note that the stops will allow
up to 3 degrees of additional rotation in both directions during impact (see Figure
3-2).
The engine must always shut down when the actuator is at the minimum stop.
CAUTION
The actuator's maximum slew rate can place stress on fuel system stops
and on the linkage between the actuator and the fuel system. Maximum
actuator speed is 900 degrees per second in both the increase and decrease
fuel directions. The ProAct II actuator's Mass Moment of Inertia (MMOI, with
inertia disc applied) is 3.67*10-3 in-lb-sec².
ProAct II actuator stops are designed to absorb 1.1 J (10 in-lbs) of kinetic energy
with 3 degrees overtravel. If the actuator travel stops are used, the linkage must
be designed to allow this 3 degree overrun.
Use good rod-end connectors with as little free play as possible. Select rod ends
which will not become loose and which will wear well during the nearly constant
movement associated with precise speed control. Low-friction, long-wearing rod
ends are available from Woodward.
The link connecting the actuator lever to the fuel-control lever must be short or
stiff enough to prevent flexing when the engine is running.
Actuator levers are available from Woodward which allow adjustment of the rod-
end location with respect to the center of the actuator shaft. The lever used must
have the correct interface for the actuator used.
Adjust the location of the rod end on the lever to achieve the desired rotation of
the actuator shaft between minimum and maximum positions. (Use as much of
the 75-degree rotation as possible—at least 60 degrees.) To increase the
amount of rotation, move the rod end closer to the actuator shaft or farther away
from the shaft controlling fuel flow. To decrease the amount of rotation used,
move the rod end farther from the actuator shaft or closer to the shaft controlling
fuel flow.
8 Woodward
Figure 3-1. Diesel Engine Travel Stops Figure 3-2. Carburetor Travel Stops
Actuator Bracket
The actuator may be installed on a bracket which attaches to the base with four
M8x1.25 (0.312-18) screws with a minimum engagement of 16 mm (0.625 inch).
The actuator may be mounted in any attitude. The actuator is weatherproof and
resistant to the corrosive effects of water and salt water. Avoid pressure washing
near the shaft seals.
The ProAct II actuator weighs 6.9 kg (15.23 lbs). The bracket and attaching
hardware must be designed to hold the weight and to withstand the vibration
associated with engine mounting. The bracket must also be designed to provide
a heat sink (heat transfer) from the actuator to the engine block. Figure 3-3
provides an illustration of the mounting bracket.
Figure 3-3. ProAct II Mounting Bracket
Woodward 9
Electrical Connections
External wiring connections and shielding requirements for a typical control
installation are shown in the plant wiring diagram (Figure 1-4).
The type and gauge of the wiring used should follow the wire length and type
shown in the System Wiring section of Chapter 6.
Shielded Wiring
All shielded cable must be twisted conductor pairs or triples. Do not attempt to tin
the braided shield. All signal lines should be shielded to prevent picking up stray
signals from adjacent equipment. Connect the shields to the correct pins on the
driver connector or wiring. Do not connect shields to the actuator ground. Wire
exposed beyond the shield should be as short as possible, not exceeding 50 mm
(2 inches). The other end of the shields must be left open and insulated from any
other conductor. DO NOT run shielded signal wires along with other wires
carrying large currents. See Woodward application note 50532, Interference
Control in Electronic Governing Systems, for more information.
Where shielded cable is required, cut the cable to the desired length and prepare
the cable as instructed below (Figure 3-4).
Figure 3-4. Preparing Shielded Wiring
1. Strip outer insulation from BOTH ENDS, exposing the braided or spiral
wrapped shield. DO NOT CUT THE SHIELD.
2. Using a sharp, pointed tool, carefully spread the strands of the shield.
3. Pull inner conductor(s) out of the shield. If the shield is the braided type,
twist it to prevent fraying.
4. Remove 6 mm (1/4 inch) of insulation from the inner conductors.
The shield must be considered as a separate circuit when wiring the system. The
shield must be carried through connectors without interruption.
Installations with severe electromagnetic interference (EMI) may require

additional shielding precautions. Contact Woodward Governor Company for
more information.
Failure to provide shielding can produce future conditions which are difficult to
diagnose. Proper shielding at the time of installation is required to assure
satisfactory operation of the ProAct control system.
10 Woodward
Power Supply
Power supply output must be low impedance (for example, directly from
batteries).
Run an insulated wire directly from the positive (+) battery terminal to the fuse
and the switch as shown in Figure 3-5, then from the switch to the correct
connection on the driver (see Figure 1-4). Run a second insulated wire directly
from the negative (–) terminal of the battery to the driver. Neither of these
connections needs to be shielded (see Figure 3-5 for correct installation).
Run the power leads directly from the power source to the control. DO NOT
POWER OTHER DEVICES WITH LEADS COMMON TO THE CONTROL. If the
power source is a battery, be sure the system includes an alternator or other
battery-charging device (see Figure 3-6 for incorrect installation).
When the engine is shut down, the driver powers the actuator to 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 use the driver for normal shutdown procedures. All actuator position
commands should come from the control unit, through the driver, to the actuator.
CAUTION
To prevent possible damage to the control, or poor control performance
resulting from ground loop problems, follow these instructions.
It is important to set up the ProAct driver in the order that follows. See
Figure 3-7 for the location of potentiometers on the driver box.
CAUTION
Always hold onto the side of the control box with one hand while making an
adjustment with the other hand. This prevents possible static damage to
parts.
Use an insulated screwdriver to make adjustments. Extensive damage is

possible should the high voltages present inside the box be shorted to
elements on the board.
Woodward 11
Figure 3-5. Correct Wiring to Power Supply
Figure 3-6. Incorrect Power Supply Wiring
12 Woodward
Figure 3-7. ProAct Driver Adjustment Locations
Position Feedback Adjustment

The driver's position feedback Gain and Offset adjustments normally don't need
to be changed unless you experience feedback values outside the normal
operating parameters of the driver. If the characteristic falls outside the tolerance
limits, adjust System Position FB Gain and Offset as required to get the
characteristic midway between the tolerance limits (see Figure 3-7 for adjustment
locations).
The procedure for adjusting the system position feedback is as follows.
To set up the driver system feedback, first disconnect the actuator drive wires at
the control (DO NOT disconnect the actuator position feedback wires). Power up
the system with the actuator disconnected from the linkage but with the inertia
disk in place. DO NOT START THE ENGINE AT THIS TIME.
The actuator can be manually moved between minimum and maximum fuel,
based on actuator stops. Adjust the System Position FB (feedback) Gain and
Offset potentiometers until the output at the terminals is within the desired
specification. The nominal voltages are 0.5 V at minimum fuel and 4.5 V at
maximum fuel.
Woodward 13
NOTE
The adjustment of the system position feedback potentiometers does not
affect the positioning of the actuator relative to the position input signal, or
the response of the actuator to the position input signal.
Reconnect the actuator drive wires.
Actuator Travel
The driver's Gain and Offset adjustments normally don't need to be changed
unless you experience difficulty getting the actuator to travel full stroke. If the
characteristic falls outside the tolerance limits, adjust Position Command Gain
and Offset as required to get the characteristic midway between the tolerance
limits (see Figure 3-7 for adjustment locations).
To set up the driver and actuator, power up the system with the actuator
disconnected from the linkage but with the inertia disk in place. DO NOT START
THE ENGINE AT THIS TIME.
Vary the signal into the position input to the driver and observe actuator angle.
Adjust the Position Command Gain and Offset potentiometers to achieve the
desired relationship (see Figure 3-7). Failure to make this adjustment correctly
may result in the inability to shut off fuel or the inability to reach full-fuel position.
After this adjustment is made, re-install linkage, coupling, etc., to the engine.
This procedure must be repeated whenever the actuator or driver is changed.

The Gain and Offset pots are both located on the printed circuit board inside the
driver box.
The actuator position feedback sensor is factory set and should not be adjusted.
14 Woodward
Chapter 4.
Description of Operation
The ProAct™ control system functions by receiving a position command signal

from a Woodward electronic governor. The system then sends a pulse width
modulated current (–12 A to +12 A) signal to the actuator, modified by signals
from a position feedback, velocity, and current sensor from the actuator (Figure
4-1).
Figure 4-1. ProAct II Functional Block Diagram
Electronic Circuits
All circuits in the ProAct driver are solid state and are not serviceable in the field.
The printed circuit board is manufactured by Woodward to provide maximum
tolerance to temperature and vibration.
Four potentiometers, accessible when the cover of the driver box is removed,
provide all adjustments to the driver system.
A 25-turn pot (Position Command Gain) adjusts how far the actuator travels
when the speed control signal varies from minimum to maximum.
Woodward 15
A 25-turn pot (Position Command Offset) adjusts the offset of the actuator travel
when the speed control signal varies from minimum to maximum.
A 25-turn pot (System Position Feedback Gain) adjusts the system position
feedback gain as the actuator varies from minimum to maximum.
A 25-turn pot (System Position Feedback Offset) adjusts the system position
feedback offset as the actuator varies from minimum to maximum.
Actuator Position Signal

The feedback device is located on the closed shaft of the actuator. The device is
a rotary transducer which changes resistance proportional to the location of the
shaft. The device is a non-contacting unit, thereby eliminating most wear
problems.
Actuator
The rotary design of the ProAct actuators gives 75 degrees of shaft rotation to
position fuel controls. The actuators apply torque in both directions. Torque is
proportional to the current supplied to the actuator by the driver.
The actuator uses sealed bearings, eliminating the need for maintenance. The
feedback mechanism attaches to the end of the rotor not being used to control
the engine. The device is enclosed in a Ryton housing and is sealed against the
elements. Avoid pressure washing the actuator.
An inertia disc is installed on the actuator output shaft. The disc is necessary for
stable actuator operation with light, low-friction linkages. Do not remove the disc
(see Figure 1-3).
16 Woodward
Chapter 5.
Troubleshooting
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.
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 installation problems 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 fuel-control 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 position 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.
Linkage and Actuator Stroke

Use as much of the 75 degrees of actuator stroke as possible. Carefully follow the
guidelines in the Actuator Installation section of Chapter 3 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.
Possible problems with driver-actuator system include:

Symptom Possible Cause Possible Fix 1 Possible Fix 2
Actuator drives opposite Actuator drive and Actuator drive wires and
direction than the position feedback position feedback (both)
command signal directs. signals are connected may be connected in the
incorrectly. reverse polarity. Check
wiring for proper polarity.
Actuator drives into max Actuator drive or Actuator drive wires may be Actuator position feedback
stop with a command to position feedback connected in the reverse input may be connected in
min fuel applied. signals are connected polarity. Check wiring for the reverse polarity. Check
incorrectly. proper polarity. wiring for proper polarity.
Actuator drives into min Position command Position command input Position command input
stop with a command to signal is not being leads may be connected in may have poor connection
mid fuel (or some other received correctly. wrong polarity. Check to input signal. Check wiring
non-stop command) wiring for proper polarity. for good connection.
applied.
Actuator and control Actuator and driver is Input power leads may be Input power leads may
system do not respond— not receiving power. connected in wrong have poor connection to
all voltage outputs are 0 polarity. Check wiring for battery + or battery –.
V. proper polarity. Check wiring for good
connection.
Woodward 17
Chapter 6.
Technical Specifications
Power Supply
The power supply for the ProAct™ II driver is configured to operate from 20 to 32
Vdc. The minimum current level to be provided by the system will be 6 A dc and
12 A dc for up to two seconds.
Actuator Position Feedback

The actuator position feedback output provides a nominal 0.5 to 4.5 Vdc
corresponding to 0% to 100% actuator travel. The actuator position feedback will
filter the position output signal using a low-pass filter with a cut-off frequency of
40 Hz. The actuator position output has gain and offset adjustments to trim the
voltage output for the proper voltages at the correct positions.
System Wiring
The actuator driver is capable of driving the actuator through wiring harnesses of
the following configurations:
The maximum length of the line distance between the battery summed with twice
the distance between the control and the actuator must be less than the distance
in the following chart.
Actuator Position Actuator Position

Line Length Driver Wire Gauge Feedback Wire Gauge Feedback Wire Type
0–3 m 1.5 mm² (16 AWG) or 0.5 mm² (20 AWG) or twisted shielded triple
(0–10 ft) larger stranded larger stranded
3–6 m 2 mm² (14 AWG) or 0.5 mm² (20 AWG) or twisted shielded triple
6–10.5 m 4 mm² (12 AWG) or 0.5 mm² (20 AWG) or twisted shielded triple
10.5–16.8 m 6 mm² (10 AWG) or 0.5 mm² (20 AWG) or twisted shielded triple
Under no circumstances should the maximum length calculated using the

formula above be greater than 16.8 m (55 ft).
In applications where these maximum line lengths are followed, the worst case
transient current level at elevated actuator temps (100 ºC ambient) will be 57.5%
of the transient limit. This only affects the transient current limits, the steady state
limits will still be 6 A.
18 Woodward
Input Configurations
The following input configurations are available for the position command input.
PWM
The PWM input will accept a 1000±100 Hz input signal of 5 to 32 V peak voltage
(referenced to unit battery ground). The nominal input of 10% to 90% duty cycle
will correspond to 0% to 100% actuator travel (at system calibration
temperature). 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 inputs.
0–200 mA
The 0–200 mA input will accept a 0 to 200 mA dc input. The nominal input of 20
to 160 mA will correspond to 0% to 100% actuator travel (at system calibration
for all inputs.
4–20 mA
The 4–20 mA input will accept a 0 to 20 mA dc input. The nominal input of 4 to
20 mA will correspond to 0% to 100% actuator travel (at system calibration
for all inputs.
11–20 mA
for all inputs.
4–13 mA
for all inputs.
0–5 Volt
The 0–5 V input will accept a 0 to 5 Vdc input. The nominal input of 0.5 to 4.5 V
will correspond to 0% to 100% actuator travel (at system calibration
for all inputs.
System Performance
The performance of the driver when mated to a ProAct II actuator will be as
follows:
Inertia level
The driver mated to a ProAct II actuator can drive inertial loads not to exceed
5.9*10–3 in-lb-sec². This is specified as un-damped direct inertia.
Woodward 19
Actuator compliance
The actuator compliance will be to reach peak steady-state torque in less than
5% of actuator full travel, external deflection of the actuator from commanded
position for all supply voltages and current levels within the specified power
supply ranges.
Actuator slew rate

The actuator slew rate will be between 80 ms and 100 ms for a 10% to 90% or
90% to 10% actuator slew, commanded with the appropriate input square wave
for all supply voltages, current levels and inertial loads within the specified
ranges.
Small signal bandwidth

The small signal (1% of full stroke actuator travel sine wave actuator drive)
bandwidth of the driver for command to position will be between 6 and 8 Hz for
the –3 dB point and 3 and 4 Hz for –45 degree phase loss point, for all supply
voltages, current levels, and actuator load inertias within the specified ranges.
Large signal bandwidth

The large signal (10% of full stroke actuator travel sine wave actuator drive)
bandwidth of the driver for command to position will be between 10 and 15 Hz for
the –3 dB point and between 4 and 5 Hz for the –45 degree phase loss point, for
all supply voltages, current levels, and actuator load inertias within the specified
ranges.
Position accuracy
The position accuracy for command to position will be better than 1% of actuator
full travel after the unit has been calibrated to the actuator for gain and offset.
This accuracy is valid at the calibration temperature of the actuator assembly. If
the actuator assembly temperature is different from the calibration temperature,
the position error will be less than 20% over the entire temperature range. The
temperature deviation is a negative tolerance. This means that the unit will drift
such that minimum fuel and maximum fuel is always reachable using the
standard input range. However, the unit may reach minimum or maximum fuel at
input percentages 20% less than (in the case of maximum fuel) or greater than
(in the case of minimum fuel) the nominal range.
Unit-to-unit position accuracy

The unit-to-unit position accuracy for two units that have been calibrated and are
mounted on the same engine, operating from the same command signal and at
the same temperature, will be less than 5% for all actuator temperatures within
the specified operating range.
System protection
The system contains protection circuitry to prevent damage if the power supply
circuits are connected in reverse polarity. The unit also contains circuitry to
prevent driver and actuator damage if one of the actuator wires is short-circuited
to battery positive or ground, or if one actuator wire is shorted to the other. The
result will be an actuator shutdown during the period of the short circuit. The unit
also contains circuitry to prevent driver and actuator damage if the driver steady-
state current rises above 6 A continuously. The result will be an actuator
shutdown.
20 Woodward
Chapter 7.
Service Options
Product Service Options

The following factory options are available for servicing Woodward equipment,
based on the standard Woodward Product and Service Warranty (5-01-1205)
that is in effect at the time the product is purchased from Woodward or the
service is performed:
• Replacement/Exchange (24-hour service)
• Flat Rate Repair
• Flat Rate Remanufacture
If you are experiencing problems with installation or unsatisfactory performance

of an installed system, the following options are available:
• Consult the troubleshooting guide in the manual.
• Contact Woodward technical assistance (see “How to Contact Woodward”
later in this chapter) and discuss your problem. In most cases, your problem
can be resolved over the phone. If not, you can select which course of
action you wish to pursue based on the available services listed in this
section.
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 is also a flat rate structured program and
includes the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205).
This option allows you to call 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 Woodward facility as explained below (see “Returning Equipment
for Repair” later in this chapter).
Charges for the Replacement/Exchange service are based on a flat rate plus
shipping expenses. You are invoiced the flat rate replacement/exchange charge
plus a core charge at the time the replacement unit is shipped. If the core (field
unit) is returned to Woodward within 60 days, Woodward will issue a credit for
the core charge. [The core charge is the average difference between the flat rate
replacement/exchange charge and the current list price of a new unit.]
Return Shipment Authorization Label. To ensure prompt receipt of the core,

and avoid additional charges, the package must be properly marked. A return
authorization label is included with every Replacement/Exchange unit that leaves
Woodward. The core should be repackaged and the return authorization label
affixed to the outside of the package. Without the authorization label, receipt of
the returned core could be delayed and cause additional charges to be applied.
Woodward 21
Flat Rate Repair

Flat Rate Repair is available for the majority of standard 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. All repair work carries the standard
Woodward service warranty (Woodward Product and Service Warranty
5-01-1205) on replaced parts and labor.
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 “like-new” condition and carry
with it the full standard Woodward product warranty (Woodward Product and
Service Warranty 5-01-1205). 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 to Woodward for
repair, please contact Woodward in advance to obtain a Return Authorization
Number. When shipping the item(s), attach a tag with the following information:
• 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.
CAUTION
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.
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.
22 Woodward
Return Authorization Number

When returning equipment to Woodward, please telephone and ask for the
Customer Service Department [1 (800) 523-2831 in North America or
+1 (970) 482-5811]. They will help expedite the processing of your order through
our distributors or local service facility. To expedite the repair process, contact
Woodward in advance to obtain a Return Authorization Number, and arrange for
issue of a purchase order for the item(s) to be repaired. No work can be started
until a purchase order is received.
NOTE
We highly recommend that you make arrangement in advance for return
shipments. Contact a Woodward customer service representative at
1 (800) 523-2831 in North America or +1 (970) 482-5811 for instructions and
for a Return Authorization Number.
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.
How to Contact Woodward

In North America use the following address when shipping or corresponding:
Woodward Governor Company
PO Box 1519
1000 East Drake Rd
Fort Collins CO 80522-1519, USA
Telephone—+1 (970) 482-5811 (24 hours a day)

Toll-free Phone (in North America)—1 (800) 523-2831
Fax—+1 (970) 498-3058
For assistance outside North America, call one of the following international
Woodward facilities to obtain the address and phone number of the facility
nearest your location where you will be able to get information and service.
Facility Phone Number

Brazil +55 (19) 3708 4800
India +91 (129) 230 7111
Japan +81 (476) 93-4661
The Netherlands +31 (23) 5661111
You can also contact the Woodward Customer Service Department or consult
our worldwide directory on Woodward’s website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility.
Woodward 23
Engineering Services
Woodward Industrial Controls Engineering Services offers the following after-
sales support for Woodward products. For these services, you can contact us by
telephone, by email, or through the Woodward website.
• Technical Support
• Product Training
• Field Service
Contact information:
Telephone—+1 (970) 482-5811
Toll-free Phone (in North America)—1 (800) 523-2831
Email—[email protected]
Website—www.woodward.com
Technical Support is available through our many worldwide locations or our

authorized distributors, depending upon the product. This service can assist you
with technical questions or problem solving during normal business hours.
Emergency assistance is also available during non-business hours by phoning
our toll-free number and stating the urgency of your problem. For technical
support, please contact us via telephone, email us, or use our website and
reference Customer Services and then Technical Support.
Product Training is available at many of our worldwide locations (standard

classes). We also offer customized classes, which can be tailored to your needs
and can be held at one of our locations or at your site. This training, conducted
by experienced personnel, will assure that you will be able to maintain system
reliability and availability. For information concerning training, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Product Training.
Field Service engineering on-site support is available, depending on the product

and location, from one of our many worldwide locations or from one of our
authorized distributors. The field engineers are experienced both on Woodward
products as well as on much of the non-Woodward equipment with which our
products interface. For field service engineering assistance, please contact us
via telephone, email us, or use our website and reference Customer Services
and then Technical Support.
24 Woodward
Technical Assistance
If you need to telephone for technical assistance, you will need to provide the following information.
Please write it down here before phoning:
General
Your Name
Site Location
Phone Number
Fax Number
Prime Mover Information

Engine/Turbine Model Number
Manufacturer
Number of Cylinders (if applicable)
Type of Fuel (gas, gaseous, steam, etc)
Rating
Application
Control/Governor Information
Please list all Woodward governors, actuators, and electronic controls in your system:
Woodward Part Number and Revision Letter
Control Description or Governor Type
Serial Number
Serial Number
Serial Number
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.
Woodward 25
26 Woodward
ProAct™ II Actuator/Driver Specifications
Driver Box:
Operating Temperature Range –40 to +70 ºC (–40 to +158 ºF)
Storage Temperature Range –55 to +105 ºC (–67 to +221 ºF)
Humidity MS810D, M507.3, P3, 95% RH@60 ºC 10 cycles, NC
Shock MS810C, M516.2, PL 40 G, 11mS Saw tooth
Vibration Random Vibration 0.04G²/Hz WGC RV2
Salt Fog MS810D, M509.2, PL 48 hrs (for IP56 version)
Power Supply 20 to 32 Vdc (24 Vdc nominal)
Current Requirements 6 A sustained; 12 A available for two seconds
Actuator:
Operating Temperature Range –40 to +100 ºC (–40 to +212 ºF)
Storage Temperature Range –55 to +125 ºC (–67 to +257 ºF)
Shock MS810C, M516.2, Procedure IV, 100 g
Vibration MS810C, M514.2, Proc. VIII, 20 g (10 g in axial direct.)
Mass Moment of Inertia ProAct II Actuator is 3.67*10-3 in-lb-sec²
(with inertia disc applied)
We appreciate your comments about the content of our publications.
Send comments to: [email protected]
Please include the manual number from the front cover of this publication.
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.
04/9/F

Installation and Operation Manual: Proact™ Ii Electric Powered Actuator and Driver

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Installation and Operation Manual

ProAct™ II Electric Powered

Electronic controls contain static-sensitive parts. Observe the following

CAUTION—indicates a potentially hazardous situation which, if not avoided, could

Revisions—Text changes are indicated by a black line alongside the text.

CHAPTER 1. GENERAL INFORMATION ........................................................... 1

Illustrations and Tables

Figure 1-1. Outline Drawing of ProAct II Driver with IP56 Box...............................2

The ProAct II driver comes in two different package configurations: a sealed

Nominal Actuator Output for Woodward

4 to 13 mA 4 to 12 mA 0% to 100% actuator position sheet metal enclosure 8400-024

Figure 1-1. Outline Drawing of ProAct II Driver with IP56 Box

Figure 1-3. Outline Drawing of ProAct Actuator

Figure 1-4. Plant Wiring Diagram

All electronic equipment is static-sensitive, some components more than others.

Follow these precautions when working with or near the control.

1. Before doing maintenance on the electronic control, discharge the static

3. Keep plastic, vinyl, and Styrofoam materials (such as plastic or Styrofoam

• Do not touch any part of the PCB except the edges.

• Do not touch the electrical conductors, the connectors, or the

The driver is capable of withstanding the following vibration specifications:

If operating temperature is a concern, contact Woodward for more information.

Fuel Position Stops

Figure 3-3. ProAct II Mounting Bracket

Figure 3-4. Preparing Shielded Wiring

4. Remove 6 mm (1/4 inch) of insulation from the inner conductors.

Installations with severe electromagnetic interference (EMI) may require

Use an insulated screwdriver to make adjustments. Extensive damage is

Figure 3-5. Correct Wiring to Power Supply

Figure 3-6. Incorrect Power Supply Wiring

Figure 3-7. ProAct Driver Adjustment Locations

Position Feedback Adjustment

The procedure for adjusting the system position feedback is as follows.

Reconnect the actuator drive wires.

This procedure must be repeated whenever the actuator or driver is changed.

The ProAct™ control system functions by receiving a position command signal

Figure 4-1. ProAct II Functional Block Diagram

Actuator Position Signal

Attempting to correct engine or load problems with untimely governor adjustment

Governor faults are usually caused by installation problems or the linkage

Linkage and Actuator Stroke

Possible problems with driver-actuator system include:

Actuator Position Feedback

Actuator Position Actuator Position

Under no circumstances should the maximum length calculated using the

Actuator slew rate

Small signal bandwidth

Large signal bandwidth

Unit-to-unit position accuracy

Product Service Options

If you are experiencing problems with installation or unsatisfactory performance

This option allows you to call in the event of an unexpected outage, or in

Return Shipment Authorization Label. To ensure prompt receipt of the core,

Flat Rate Repair

Flat Rate Remanufacture

Returning Equipment for Repair

Return Authorization Number

How to Contact Woodward

Telephone—+1 (970) 482-5811 (24 hours a day)