ACC.pdf

Eric FeilerRTR

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WELCOME!

This catalog is a concise selection of Woodward standard product lines for advanced combustion controls with specic applications in automotive testing and research and development projects. Woodward manufactures 1000s of products for OEM volume production programs ranging from the simplest combustion controls applications to the most complex in the world.

For a complete listing of other Woodward product lines, please visit www.woodward.com.

CONTENTS

Page

04 Woodward Overview

05 Woodward Product Family Overview

07 Ignition and Ion Sensing Product Overview

08 SmartFire Instrumentation Ignition

10 SmartFlame Module

12 Actuator and Throttle Body Specication Charts

13 Actuator Product Overview

14 L Series Speed Controller

16 ProAct Digital Plus Actuators

20 ProAct ISC Integrated Speed Control

25 Throttle Body Product Overview

26 L Series ITB Integrated Throttle Body

28 Flo-Tech ITB Integrated Throttle Body/Actuator

32 ProAct ITB Integrated Throttle Body

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ADVANCED COMBUSTION CONTROLS | PRODUCTS OVERVIEW

Woodward is the worlds largest independent designer, manufacturer, and service provider of energy control solutions for aircraft engines, industrial engines and turbines, power generation, and mobile industrial equipment. The companys innovative control, fuel delivery, and combustion systems help customers worldwide operate cleaner, more reliable, and cost effective equipment.

Good control solutions are more than just components and systems. Good solutions also incor-porate the experience, expertise, and analytical capabilities that Woodward brings to customers. Backed by knowledge gained from decades of managing and controlling engines of every size, type, and application, Woodward works closely with OEMs and customers at the research and development level to provide well-integrated solutions that help make todays engines and equipment operate more cleanly, reliably and efciently.

Woodward has a full range of products and control system solutions based on four key technolo-gies fuel and air delivery, combustion control, electronic controls and software, and systems inte-gration. With Woodwards fully integrated control system architecture, control system costs can be signicantly reduced while performance and network communications capabilities are enhanced.

This catalog will focus on the Woodward product lines of actuators, throttle bodies and ignition systems that are relevant to the automotive, industrial and testing markets.

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WOODWARD PRODUCT FAMILY OVERVIEW

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IGNITION AND ION SENSING PRODUCT OVERVIEW

SmartFire Instrumentation Ignition

The SmartFire ignition controller is the state of the art in combustion electronics. SmartFire and its combustion analysis software, WinFire, can be used to gather combustion data crucial for engine development and tuning with no modications to the combustion chamber.

SmartFire is the rst commercially available ignition and engine diagnostic system to fully utilize ionization feedback.

SmartFlame Module

The SmartFlame module was developed to meet the need of researchers experimenting with ion currents. It provides a simple and convenient method of creating an ion bias voltage. Since the module is totally isolated it is easy to hook up and install. This module is used in conjunction with standard off the shelf NI hardware. It allows for real time acquisition and processing of ion signals. This platform can communicate the data either digitally over a network or analog via any of the many off the shelf modules. The NI systems that hold these modules range in size from 4-module portable systems to large rack mount systems capable of holding hundreds of systems.

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The SmartFire Instrumentation Ignition system provides the most user-friendly combustion feedback tool available.

SmartFire provides individual cylinder feedback in a real time format and is designed to aid dynamometer opera-tors eager to maximize their engine performance. The SmartFire system has applications on gasoline, natural gas, diesel and HCCI engines.

On gasoline and natural gas engines the SmartFire system uses high-speed signal processing of the ion signal to detect ALL misres. When misres occur SmartFire uses closed loop re-strike to re-ignite the cylinder to prevent combustible mixtures from escaping the combustion chamber.

SmartFire detects every occurrence of pre-ignition in the cylinder this feature is not available with conventional acoustic systems. SmartFire makes it possible to calibrate engines using misre detection and prevention through the tip of the sparkplug without drilling holes.

SmartFire is capable of using ion signals to detect knock with greater sensitivity than traditional acoustic transduc-ers. SmartFire enables dynamometer operators to take full advantage of the systems unique ability to do knock calibrations where invasive cylinder pressure sensors are normally required. The system is designed to help maxi-mize engine performance.

Through in-cylinder start of combustion agging on diesel engines, closed loop injection timing control is possible with SmartFire. The system is also able to improve cold startability of diesel engines compared to traditional glow plugs.

The SmartFire system is able to provide feedback to control fuel injection and ignition timing on an individual cylinder basis. SmartFire uses ionization feedback to allow the engine builder to dial in the maximum horsepower for each individual cylinder.

The SmartFire system includes a PC interface, which al-lows the operator to view the ionization waveforms of each cylinder in real time. The system can re and monitor up to 12 cylinders.


Rapid engine calibration

Ion sensing through the tip of the sparkplugs

NO DRILLING HOLES

Knock detection

Misre Detection for OBD II

Misre Prevention

Quicker integration

Can be installed and running in as little as 3 hours

Runs on Windows 95/98/NT/XP

Knock and misre displayed on PC software

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3800 North Wilson Ave.Loveland, CO 80538

Ph: +1 (970) 962-7517 Fax: +1 (970) 962-7515

www.woodward.com/ smartfire

www.woodward.com

Advanced Combustion Controls

This document is distributed for informational purposes only. It is not to be construed as creating or becoming part of any Woodward Governor Company contractual or warranty obligation unless expressly stated in a written sales contract.

Woodward 2005All Rights Reserved.


BENEFITS Data Acquisition Ionization can be logged to either the

display PC or to the dynamometers high-speed data acquisition system.

SmartFire performs knock and misre detection in a real time format directly through the spark plug, with no extra holes to drill.

SmartFire can analyze ionization from any type of fuel.

Compatible with any engine the system provides an excellent return on investment.

SmartFires real time display is a useful tool for realtime engine development and diagnostics.

Capable of data logging on Dyno and during in car transient testing.

SmartFire eliminates drilling of any extra holes in engine to get good combustion information.

SmartFire delivers a start of combustion ag for diesel and HCCI engines.

SmartFire with its ionization feedback is the ignition technology of the future.

Peak Power Optimization individual cylinder readings make tuning much more efcient and effective; resulting in maximum performance from your engine!

SPECIFICATIONS

Input12 or 24 Volts.

Cylinder Congurations1 through 12 cylinder congurations are software selectable.

Output30KV with 160 Amps of peak spark current in high energy.

Duration100uS per spark, with up to 22 degrees of duration with one spark every 1.2mS.

CompatibilitySmartFire is Windows 95 to XP compatible and comes with an electronic instruction manual.

SmartFire Monitoring Station

Dyno Monitoring Station

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DESCRIPTION

The Woodward SmartFlame module is a precision ame ionization sensing module used to read the ionization intensity in combustion applications.

It provides a user selectable voltage from 100V to 400V and is available in positive and negative supply versions.

The SmartFlame modules utilizes far-side sensing to ensure the best signal to noise ratio.

Data is collected at a rate of 100k samples/second with a resolution of 16 bits.

These modules plug in to standard National Instruments cRIO chassis and allow for online data acquisition and signal processing. Portable chassis may accept up to eight cRIO form factor modules including D/A, A/D,

DIO, CAN and SmartFlame modules. Larger congura-tions are possible with hundreds of channels.

Software selectable gains allow online adjustment of the signal to support changes in operating condition.

Software selectable voltages of 100V, 200V, 300V, and 400V allow for extended diagnostics.

SmartFlame Module

Precision Ion Sensing module

Full Isolation

100kS/s, 16-bits

Software selectable voltage and gain

National Insturments cRIO back plane must be purchased separately

The National Instruments user interface (LabVIEW) for the SmartFlame Module

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ACTUATOR AND THROTTLE BODY SPECIFICATIONS

Actuators Integrated Throttle Bodies and Actuators

L Series ProAct Digital ProAct ISC ProAct ITB Flo-Tech ITB

L Series ITB

Model 1 Model 2 Model 3 Model 4 Model 1 Model 2 Model 2 Model 3

Travel Degrees

60 75 75 75 75 75 75 75 75 70 60

Peak SS*** Torque ftLbs

.25 1.25 2.5 5 10 1.25 2.5 2.5 5 1.1 .25

Peak TR*** Torque ftLbs

_ _ _ 2.5 5 10 20 2.5 5 5 10 2.2 _ _ _

Approx Slew Time

_ _ _ 80 80 80 80 80 80 80 80 80 _ _ _

Vol Dimensions

75.7 x88.4 x111.3

75.7 x88.4 x111.3

3.8 x5.1 x 4.7

5.26 x5.1 x 4.7

8.2 x5.1 x 4.7

3.8 x5.1 x 4.7

3.8 x5.1 x 4.7

3.8 x5.1 x 4.7

5.26 x5.1 x 4.7

2.38 xd 5.0

75.7 x88.4 x111.3

105mm 33mm 25mm

120mm 48mm 30mm

Available Throttle Body Sizes for Various Actuators 135mm 60mm 36mm

68mm 43mm

75mm 50mm

Integrated Throttle Bodies/Size Approx Output

ProAct ITB-135mmProAct ITB-120mmProAct ITB-105mm

1-2 mw For proper sizing please consult page 29.

Flo-Tech ITB- 75mmFlo-Tech ITB- 68mmFlo-Tech ITB- 60mmFlo-Tech ITB- 48mmFlo-Tech ITB- 33mm

25kw - 500kw

Integrated Throttle Bodies/Size Approx Output

L Series ITB - 50mmL Series ITB - 45mmL Series ITB - 36mmL Series ITB - 30mmL Series ITB - 25mm

15kw -100kw For proper sizing please consult page 29.

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ACTUATOR PRODUCT OVERVIEW

L Series Speed Controller

The Woodward L Series Integrated Engine Control System is the rst engine speed control to deliver so much in a package this compact, and it can also deliver a big savings in production and eld support. Since the L Series Control System is microprocessor-based, it can easily be programmed to match the operating parameters of every engine you produce. All it takes is a PC and a simple, plug-in download on your production line. With many built-in functions, this microprocessor-based speed control allows a high-volume OEM or packager to stock one part number, but implement a wide variety of engine control strategies by conguring the four auxiliary inputs at their factory.

ProAct Digital Plus Actuators

The ProAct Digital Plus actuator is intended to be mounted on-engine to control varying functions including (but not limited to): fuel rack positioning, timing control, throttle valve, and wastegate positioning. The actuator is effectively a positioner with an integral driver, which will accept a position command signal from another device in the system such as a speed control. The ProAct Digital Plus actuator includes an integral digital driver capable of controlling the actuator, communicating with the outside control system, and containing on-board software and intelligence to realize monitoring and customizing functions.

ProAct ISC Integrated Speed Control

The ProAct Integrated Speed Control (ISC) is an electric actuator with an integrated electronic driver capable of diesel or gaseous engine speed control or positioning tasks. The ProAct ISC can be mounted on-engine to control a diesel fuel rack or gaseous throttle via linkage or integrated throttle body. The ProAct ISC accepts a speed input from an MPU and can accept a position command signal from another device in the system such as an engine control module. Congured as a speed control, the ProAct ISC offers speed control with software-selectable speed set points, dynamics, fuel limiting, and start/stop behavior. Congured as a positioner, the ProAct ISC offers position control with software selectable CW/CCW operation and eld calibration.

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DESCRIPTIONThe Woodward L Series Integrated Engine Control System is the rst engine speed control to deliver so much in a package this compact.

It can also deliver a big savings in production and eld support. Since the L Series Control System is micropro-cessor-based, it can easily be programmed to match the operating parameters of every engine you produce. The L-Series offers speed control with software-selectable speed setpoints, dynamics, fuel limiting, and start/stop behavior. All it takes is a PC and a simple, plug-in down-load on your production line.

With many built-in functions, this microprocessor-based speed control allows a high-volume OEM or packager to stock one part number, but implement a wide variety of engine control strategies by conguring the four auxiliary inputs at their factory.

Besides the traditional bracket mount using external link-age, the L Series Control System is available in a variety of mechanical congurations, including one integrated into a rotary diesel fuel pump and one integrated with a throttle body (product spec 03223) or a throttle body and mixer (product spec 03222). The externally mounted systems can be congured for clockwise or counterclockwise (standard) shaft rotation for increasing fuel.

To learn more about the new L Series integrated engine control, contact Woodward today.

L Series control features:

Operates fuel or air control with 0.34 N m (0.25 lb-ft) torque (60 travel range)

State-of-the-art speed sensing and control algorithms

Comprehensive diagnostics for easy troubleshooting

End-of-line programmability simplies inventory

Optional transient smoke limiter for turbocharged diesel engines

Customer congurable auxiliary inputs available on board to match your specic application

Optional mounting kits for Stanadyne DB-series or Delphi DP200 & DP210 fuel injection pumps provides integrated control solution

Speed setpoint adjustment using Idle/Rated1/Rated2, Raise/Lower, and external analog settings

Dual sets of speed dynamics can be set by engine speed, discrete input, or even an external signal

L Series Integrated Engine Speed ControlPRODUCT SPECIFICATION

03225E

Low cost engine control

Fully integrated actuator and speed control

Small package greater design exibility

Suitable for gasoline, gaseous, and diesel fueled engines

Microprocessor-based

Tamper-resistant

Easy setup and tuning using PC-based Service Tool

Discrete output driver for fault indication

Voltage output for throttle position indication

Congurable I/O

Optional CANopen communications

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L Series Integrated Engine Speed ControlPRODUCT SPECIFICATION

03225E

Power Supply 12/24 volt system, 10 to 32 Vdc

Power Consumption Reverse polarity protection, 32 W max

Torque 0.34 N m (0.25 lb-ft)

Dimensions (WxHxL) 75.7 x 88.4 x 111.3 mm (2.98 x 3.48 x 4.38 in.)

Weight 425 g (15 oz)

Connector 12-pin Deutsch connector (DT06-12SA-P012)

Control CharacteristicsSpeed Input Magnetic pickup or ignition coiland Range MPU input: 112 000 Hz, 1720 teeth, 1 Vrms min. IGN input: 1480 Hz, 120 cylinders with rated speed up to 4000 rpm Target speed: programmable Speed range: programmableActuator Torque High-efciency torque motor; delivers 0.34 N m (0.25 lb-ft) (60 travel range) to operate fuel or air controlSteady State Fuel Type Gasoline Diesel GaseousSpeed Regulation MPU input 0.35% 0.25% 0.35% Ignition input 0.50% n/a 0.50%

Functions/Auxiliary InputsFunction Options Isochronous Speed (50 or 60 Hz); Two or Three Speed; Droop; Start Fuel Limiter; Load Sharing; Dual Dynamics; Adjustable Max Fuel Stop; Manifold Air Pressure Biased Fuel Limiter; Cold Start Timer

SPECIFICATIONS

Programming Port Programmable with Windows GUI software (9927-1222) and harness (8923-1061)I/O 05 V throttle position indication Discrete out for fault indication 4 aux inputs, congurable functions

EnvironmentOperating Temp 40 to +105 C (40 to +221 F)Storage Temp 40 to +125 C (40 to +257 F) EMC EN61000-6-2: Immunity for Industrial Environments EN61000-6-4: Emissions for Industrial Environments SAE J1113-21: Radiated Immunity (100 V/m) SAE J1113-11: Conducted Transient Immunity Pulse 5b, Suppressed Load Dump (45 V)Humidity US MIL-STD 810E, Method 507.3, Procedure IIIShock MS1-40G 11ms sawtoothVibration Random: 0.3 G2/Hz, 102000 Hz (22.1 Grms) 3 h/axis Sine: 5 G 2.5 mm peak-to-peak, 52000 Hz, 3 h/axis, 90 min dwells, 1 octave/minThermal Shock SAE J1455, Paragraph 4.1.3.2Fluid Resistance IP56 per EN60529

ComplianceCSA Class I, Division 2, Groups A, B, C, D T3CCE Compliant with EMC Directive 89/336/EECOther Compliant as a component with Machinery Directive 98/37/EC

Technical Manual 26250

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APPLICATIONSThe ProAct Analog product line is a family of electric actuators intended to be mounted on-engine to control varying functions including (but not limited to): fuel rack positioning, timing control, throttle valve, and wastegate positioning. The actuator is effectively a positioner with an integral driver, which will accept a position command signal from another device in the system such as a speed control.

In addition, the ProAct Digital Plus actuators include an integral digital driver capable of controlling the actua-tor, communicating with the outside control system, and containing on-board software and intelligence to realize monitoring and customizing functions.

DESCRIPTIONThe actuators are designed to be base- or ange-mounted (Model IV is basemounted only) in an on-engine environ-ment and can therefore withstand high levels of vibration and temperature extremes. They all have a 0.625-36

serrated tooth terminal shaft, and an optional rotation scale and indicator are available for visible travel detection. The actuators accept analog or PWM position command signals. In addition, the Digital Plus driver accepts CAN position command signals and can be congured for re-dundant command signals. It monitors all available internal and external signals, and annunciates any detected faults through a discrete output. An analog output provides actual position indication, and a discrete input is available to remotely shut down the actuator.

Additional features of the Digital Plus driver include on-line and off-line diagnostics, current limiting based on driver electronics temperature, CAN communications, and service port communications. The Digital Plus driver is eld programmable, allowing a single design to be used in many different applications. It must be congured and calibrated to the specic engine with a personal com-puter (PC) and a Woodward Watch Window Service Tool that communicates serially to the driver via RS-232 using Woodwards DDE ServLink protocol. Watch Window Standard can be ordered from Woodward on a CD-ROM (part number 1796-065), or it can be downloaded from the Woodward website (www.woodward.com). Data les for subsequent applications of the same engine model can be downloaded offengine. The ProAct Analog actuator/driver can be congured without a service tool.

Refer to manual 26112 for more detailed information on the ProAct Digital Plus actuator, and to manual 26147 for more information on the ProAct Analog.

ProAct Analog and Digital Plus Electric Actuators with Integral Driver

PRODUCT SPECIFICATION

03231F

Extremely fast, bi-directional actuator, electronically posi-tioned in both directions

All-electric actuator requires no drive or hydraulic supply

Integral driver com-patible with broad range of control systems

75 (2) rotary output allows direct coupling to buttery, eliminating linkage

Multiple sizes to t broad range of applications

Digital Plus:

Single or redundant position command signals

Congurable parameters to tailor to varied applications

CAN communications

Advanced Diagnostics

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03231FProAct Analog and Digital Plus Electric Actuators with Integral Driver

GENERAL SPECIFICATIONS Minimum Work Output Maximum Input Power Maximum Current

Actuator Model

Part Number Weight Transient Steady State Transient Continuous Transient Steady State

Model I Analog

Digital Plus

10.5 kg (24 lbs)

11 kg (25 lbs)

3.4 J2.5 ft-lbs

1.7 J1.25 ft-lbs

67 W 19 W 3.7 A 1 A

Model II Analog

Digital Plus

10.5 kg (24 lbs)

11 kg (25 lbs)

7 J5 ft-lbs

3.4 J2.5 ft-lbs

251 W 65 W 14 A 4 A

Model III Digital Plus 15 kg (32 lbs) 14 J10 ft-lbs

7 J5 ft-lbs

282 W 73 W 15.6 A 4 A

Model IV Digital Plus 24 kg (52 lbs) 27 J20 ft-lbs

14J10 ft-lbs

370 W 100 W 20.6 A 5.6 A

END USER I/O DESCRIPTIONAnalog Digital Plus

Power Input 1832 Vdc 1832 Vdc with out-of-range diagnostics

Command Input PWM: 732 V, 1503100 Hz Analog: 20180 mA, 420 mA, & 0.54.5 Vdc

PWM: 732 V, 100 to 3000 Hz Analog: 20180 mA or 420 mA CAN

Position Feedback Output

0.5 Vdc and 4.5 Vdc corresponds to full CCW and CW, respectively

4 mA and 20 mA corresponds to 0% and 100% actuator position

Discrete Inputs Not Applicable Low Power standby mode Four CAN address combinations

Discrete Output Not Applicable Normally ON turns OFF to indicate a detected fault

RS-232 Serial Communications

Not Applicable 9-pin sub-D male connector for con-nection to PC Service Tool

CAN 2.0B Serial Communications (optional)

Not Applicable Complies with SAE J1939 but uses proprietary group extensions. Supports position command signal and monitor-ing of all shutdown and alarm condi-tions as well as some system variables.

ENVIRONMENTAL SPECIFICATIONSAcceptable Range or Qualication Condition

Comments

Operating Temperature Limits

Analog: 40 to +74 C.Digital Plus: 40 to +85 C. Under all con-ditions the Temperature Monitoring Zone must remain below 90 C.

See Mechanical Installation sec-tion of manual for discussion of this specication item.

Storage Temp 40 to +125 C, unpowered.

Vibration Qualication Test

Sine: 3.2 mm peak-to-peak for 2-39.4 Hz, 10 G for 39.4-300 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.

Shock Qualication Test

MS140G 11ms sawtooth.

Ingress Protection IP56 per EN 60529:1992.

Humidity Qualication Test

60 C, 95% RH for ve days at one cycle per day.

Chemical Resistance

The actuator uses materials proven capable of withstanding nor-mal engine environment chemicals per SAE J1455, such as diesel fuel, engine oil, and antifreeze.

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03231FProAct Analog and Digital Plus Electric Actuators with Integral Driver

ProAct Digital Plus Outline Drawing (Do not use for construction.)

ProAct Analog Outline Drawing(Do not use for construction.)

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03231F

SPECIFICATIONSMax Slew Rate > 1000 degrees/second> 18.5 rad/s (10% to 90% travel)

Position Feedback Accuracy Analog 5% of full scale from 40 to +90 C Digital Plus < 1.5% of full stroke at 25 C after calibration and 1.5% linearity < 400 ppm/C, maximum after calibration

Position Feedback Linearity Digital Plus < 1.5% of full stroke at 25 C after calibration

Position Feedback Repeatability Digital Plus < 1.5% of full stroke at 25 C after calibration

CERTIFICATIONS, AGENCY LISTINGS, AND REGULATORY COMPLIANCEEuropean Compliance for CE Mark EMC Directive: Declared to 89/336/EEC COUNCIL DIREC-

TIVE of 03 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility.

Other European Compliance Machinery Directive: Compliance as a component with 98/37/

EC COUNCIL DIRECTIVE of 23 July 1998 on the approxima-tion of the laws of the Member States relating to machinery.

Agency Listings CSA and UL/cUL for ordinary locations (Digital Plus only) CSA Class I, Div 2 component listing (standard with Analog;

optional upgrade with Digital Plus) Marine Type Approved by Lloyds Register of Shipping for

ENV1, ENV2, ENV3, and ENV4 (Digital Plus only)

ProAct Analog and Digital Plus Electric Actuators with Integral Driver

CUSTOMER ELECTRICAL CONNECTIONSProAct AnalogThe standard actuator is equipped with a 7-pin MS-style connector.

ProAct Digital PlusThe standard actuator is designed with a blank cover for use with a gland tting or a custom connector to be supplied by the customer. All inputs and outputs to the ProAct actuator are accessed beneath the end cover, which is fastened with 6 M4x10 mm screws. Input power is connected to size M4 screws, and the wires must be terminated with insulated spade or ring lugs. The I/O terminal blocks are screwless cage-clamp-style blocks that accept wires from 0.203.3 mm2 (2412 AWG) wire.Actuators with an MS-style connector mounted as an option on the end cover are also available. For OEMs, other factory- installed connectors may also be considered.

Technical ManualAnalog 26147Digital Plus 26112

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APPLICATIONSThe ProAct Integrated Speed Control (ISC) is an elec-tric actuator with an integrated electronic driver capable of diesel or gaseous engine speed control or position-ing tasks. The ProAct ISC can be mounted on-engine to control a diesel fuel rack or gaseous throttle via linkage or integrated throttle body. The ProAct ISC accepts a speed input from an MPU and can accept a position command signal from another device in the system such as an en-gine control module.

Congured as a speed control, the ProAct ISC offers speed control with softwareselectable speed set points, dynamics, fuel limiting, and start/stop behavior.

Congured as a positioner, the ProAct ISC offers position control with software selectable CW/CCW operation and eld calibration.

DESCRIPTIONThe ProAct ISC can be base or ange mounted on-engine, and will withstand high levels of vibration and temperature. The output shaft is a 0.625-36 serrated tooth shaft. Two levels of output torque are available. The ProAct ISC will also mount directly to Woodward integrated throttle bodies. The control accepts a speed input signal from a variable reluctance speed sensor, commonly called an MPU. The control may also be user-congured as a positioner accept-ing an analog position command signal. Future options will include a CAN Open communication capability.

The ProAct ISC offers a wide variety of speed control fea-tures: Dynamics settings, dual rated speed setting, idle/rated speed setting, raise or lower speed modier, analog input speed modier, analog raise and lower speed modier, droop, dual dynamics, analog outputs, and discrete out-puts. The control also allows isochronous load sharing, and monitors key internal and external signals, and annunciates any detected faults through a discrete output. An analog output provides actual position indication, and a discrete input is available to remotely shut down the control.

Additional features of the ProAct ISC include on-line and off-line diagnostics, current limiting based on driver electronics temperature, and service port communica-tions. The control is eld programmable, allowing a single design to be used in many different applications. It must be congured and calibrated to the specic engine with a personal computer (PC) and the ProAct ISC Service Tool that communicates serially to the control via RS-232 using Woodwards DDE ServLink protocol. The ProAct ISC Ser-vice Tool can be downloaded from the Woodward website (www.woodward.com/ic/software/).

Refer to manual 26246 for more detailed information on the ProAct Integrated Speed Control.

ProAct ISC Integrated Speed Control Electric Actuator with Integral Speed Control or Position Driver


03326

Extremely fast, bi-directional electric actuator, electroni-cally positioned in both directions

All-electric actuator requires no drive or hydraulic supply

Integral driver compatible of recip engine speed control or positioning tasks

75 (2) rotary output allows direct coupling to buttery, eliminating linkage

Two sizes to t broad range of applications

Congurable parameters to tailor to varied applications

Advanced Diagnostics

PAGE | 21


03326ProAct ISC Integrated Speed Control Electric Actuator with Integral Speed Control or Position Driver

GENERAL SPECIFICATIONS Minimum Work Output Maximum Input Power Maximum Current

Actuator Model

Typical Part Number

Weight Transient Steady State Transient Continuous Transient Steady State

Model I 8404-203 10.5 kg24 lbs

2.5 J22 in-lb

1.25 J11 in-lb

63 W 36 W 3.5 A 2 A

Model II 8404-204 10.5 kg24 lbs

5 J44 in-lb

2.5 J22 in-lb

198 W 63 W 11 A 3.5 A

END USER I/O DESCRIPTIONSpeed Control Conguration Positioner Conguration

Power Input 1832 Vdc 1832 Vdc

Command Input MPU (Magnetic Pickup) frequency input. 160 Vrms. 124 kHz Analog: 420 mA, 05Vdc, 3 Vdc

Position Feedback Output Available, see Analog Output below. 4 mA and 20 mA corresponds to 0% and 100% actuator position.

Available, see Analog Output below. 4 mA and 20 mA corresponds to 0% and 100% actuator position.

Analog Inputs 420 mA, 05 Vdc, 3 Vdc See Command Input

Analog Outputs 1 Available. 420 mA, 450 load 1 Available. 420 mA, 450 load

Discrete Inputs 5 Available. Software selectable High / Low or Active Open / Closed 5 Available. Software selectable High / Low or Active Open / Closed

Discrete Output 1 Available. Low side switch. 0.5 A 1 Available. Low side switch. 0.5 A

RS-232 Serial Communications

Used for Service Tool Communications. Integral with main connector. Used for Service Tool Communications. Integral with main connector.

CAN 2.0B Serial Communications Available for Boost Fuel Limit function Hardware installed, future availability

ENVIRONMENTAL SPECIFICATIONSAcceptable Range or Qualication Condition

Operating Temperature Limits 40 to +85 C

Storage Temperature 40 to +125 C, unpowered

Vibration Qualication Test RV2: US MIL -STD-202F, procedure 214A: 0.1 G2 / Hz, 102000 Hz, 3 hr /axis, 12.8 Grms Swept Sine 525 Hz, 1.6 mm, 25100 Hz 4.0 G

Thermal Shock Qualication Test Reference: SAE J1455, Paragraph 4.1.3.2 50 cycles from 40 oC to +125 oC. Unit unpowered.

Ingress Protection IP56 per EN 60529:1992.

Humidity Qualication Test 60 C, 95% RH for ve days at one cycle per day.

Chemical Resistance The actuator uses materials proven capable of withstanding normal engine environment chemicals per SAE J1455, such as diesel fuel, engine oil, and antifreeze.

PAGE | 22


03326ProAct ISC Integrated Speed Control Electric Actuator with Integral Speed Control or Position Driver

ProAct Integrated Speed Control(Do not use for construction.)

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03326

SPECIFICATIONS

Max Slew Rate > 1000 degrees/second> 18.5 rad/s (10% to 90% travel)

Position Control Accuracy3% of full scale

Steady State Speed Band0.5% of rated speed

Technical Manual26246

ProAct ISC Integrated Speed Control Electric Actuator with Integral Speed Control or Position Driver

ProAct Integrated Speed Control(Do not use for construction.)

REGULATORY COMPLIANCE

CE Compliance: Compliant with EMC and Machinery Directives

Agency Listings: CSA Class 1, Division 2, Groups A, B, C, and D per CSA for

Canada and US nonhazardous locations only.

CUSTOMER ELECTRICAL CONNECTIONS

ProAct ISCThe ProAct ISC is equipped with a 24 pin MS-style connector.

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THROTTLE BODY PRODUCT OVERVIEW

L Series ITB Integrated Throttle Body

The L Series ITB is a member of Woodwards Integrated Throttle Body family. Several throttle body size congurations (between 25 and 50 mm) are integrated with speed control or actuator options for use on gaseous fueled industrial engines between 5 and 100 kW (7 and 134 hp). Applications include automotive, power generation, refrigeration units, pumps, irrigation, mobile industrial, and gas trim valves. The L Series ITB integrated throttle body and speed control or actuator provides a building block approach to total engine management. This modular design consists of a die-cast aluminum throttle body plus a fully programmable integrated digital speed control and bi-direc-tional actuator.

Flo-Tech ITB Integrated Throttle Body/Actuator

The Flo-Tech ITB integrated throttle body and actuator is designed for direct replacement of manual throttle bodies, and is designed with ow shaping to assist in engine idle stability. The throttle body will provide equivalent maximum ow rates of standard buttery throttle bodies of the same diameter. The system contains a return spring to fully comply with DOT 571.124 speci-cations. Determination of the proper size requires a knowledge of the absolute pressure drops across the valve, the expected temperature of the gaseous media owing, and the density of the gas. Cv (volume coefcients) are provided to determine the ow vs. angle. For initial testing, a valve body diameter similar to the one typically used on the application can be used. The Flo-Tech integrated actuator/throttle body requires no actuator or linkage.

ProAct ITB Integrated Throttle Body

The ProAct ITB integrated throttle body includes 107 mm, 120 mm, and 135 mm bore sizes, and is designed for use with engines in the 1-2 MW range. These large ITB units are made to couple directly to Woodwards ProAct actuators (an electromagnetic, 75-degree device), and therefore alleviate the problems associated with linkages on gas engines, such as non-linearity and wear. This direct combination of throttle and actuator results in excellent low-load stability and transient characteristics, and requires no hydraulics, pneumatics, or governor gear train.

PAGE | 26

APPLICATIONSThe L Series ITB is a member of Woodwards Integrated Throttle Body family. Several throttle body size congura-tions (between 25 and 50 mm) are integrated with speed control or actuator options for use on gaseous fueled industrial engines between 5 and 100 kW (7 and 134 hp). Applications include power generation, refrigeration units, pumps, irrigation, mobile industrial, and gas trim valves.

The integrated throttle body incorporates the proven Woodward L Series speed control or L Series actuator, which operates the throttle plate. The L Series ITB Speed Control can be programmed via the RS-232 port of a per-sonal computer to a variety of congurations, as follows:

Isochronous speed control Droop Auxiliary input Dual dynamics Adjustable ramp time Self-tuning gain

Overspeed/underspeed protection Remote speed setting Three speed select Error relay driver

The L Series Actuator comes in two basic congurations with or without on-board nal drivers. The onboard driver version accepts a 732 Vdc, 1503100 Hz PWM posi-tion command signal. The version without drivers brings the actuator coil (4 @ 25 C, 14 mH @ 500 Hz) leads directly out to the Deutsch connector. The L Series Actua-tor also has an optional, integral 05 Vdc throttle position feedback signal.

DESCRIPTIONThe L Series ITB integrated throttle body and speed con-trol or actuator provides a building block approach to total engine management. This modular design consists of a die-cast aluminum throttle body plus a fully programmable integrated digital speed control and bi-directional actuator.

The throttle body incorporates a corrosionprotected, plat-ed steel shaft, plate, and a sealed ball-bearing design for durability and long life. An internal throttle return spring is standard to close the throttle in the event of power failure.

The modular design of the L Series ITB system reduces total engine assembly cost, eliminates external linkages, lowers inventory and part number proliferation. The pro-grammable controller offers security to your conguration.

The L Series ITB speed control is compatible with Wood-wards venturi-style mixer and other brands of gas mixers using suitable adapters (see L Series product specication 03225 for speed control details and operating parameters).

L Series ITB Integrated Throttle Bodyand Speed Control or Actuator


03223

Integrated, bi-direc-tional actuator or OEM-congurable speed control

Eliminates external linkages

Reduces total engine assembly costs

Can be used in turbocharged applications with throttle pressure higher than ambient

Optional PWM input positioner model with integral position feedback

Sealed ballbearing throttle body design

Full range of bore sizes available: 25, 30, 36, 43, 50 mm

Tamperproof

End-of-line program-mable speed control

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Ph: +1 (970) 962-7517 Fax: +1 (970) 962-7515


www.woodward.com




L Series ITB Integrated Throttle Bodyand Speed Control or Actuator


03223


SPECIFICATIONS

Representative Drawing of 30 mm L Series ITB Control (Do not use for construction)

Representative Drawing of 50 mm L Series ITB Control (Do not use for construction)

PAGE | 28

APPLICATIONSThe Flo-Tech ITB integrated throttle body and actua-tor is designed with ow shaping to assist in engine idle stability. The throttle body will provide equivalent maximum ow rates of standard buttery throttle bodies of the same diameter. The system contains a return spring to fully com-ply with DOT 571.124 specications. Determination of the proper size requires a knowledge of the absolute pressure drops across the valve, the expected temperature of the gaseous media owing, and the density of the gas. Cv (volume coefcients) are provided to determine the ow vs. angle. For initial testing a valve body diameter similar to the one typically used on the application can be used.

The Flo-Tech ITB is designed for direct replacement of manual throttle bodies. It requires no actuator or linkage.

DESCRIPTIONThe Flo-Tech family of electrically actuated throttles/valves controls ow. The ow is a function of throttle position and pressure drop. The throttle position is proportional to the position command signal.

The Flo-Tech ITB can be made with 33, 48, 60, 68, and 75 mm bore sizes for various applications. Command input options come in PWM, 05 Vdc, 420 mA, and 0200 mA. Position feedback output signal will vary from 0.5 0.1 volts to 4.5 0.1 volts nominal at the min and max actuator position respectively. The PWM command input version will return to minimum actuator position with a command of greater than 95% duty cycle.

The Flo-Tech actuator requires a power supply of 932 Vdc. The supply must be capable of supplying a sustained 25 watts at steady-state and 50 watts for transient state conditions for at least 0.25 second.

Flo-Tech ITB Integrated Throttle Body and Actuator


04140B

No linkage or couplings

Cost-effective and highly efcient

Extremely low maintenance product

Small size for easy installation

Conveniently integrated electronics

Includes return-spring to fully comply with DOT 571.124 specs

Versatile 12 or 24 Vdc operation

PAGE | 29


04140BFlo-Tech ITB Integrated Throttle Body and Actuator

INSTALLATIONThe Flo-Tech ITB integrated throttle body and actuator may be mounted in any position. Both mounting anges on the throttle body have four 10 mm through-holes in a square, 74 mm pattern. The base of the unit has an optional bolt pattern that can be used for mounting sup-port. It uses 4 M8x0.125 bolts in an 88.9 mm square pattern. The connector to the Flo-Tech actuator is a Packard Electric male connec-tor. The mating connector is a Packard female connector (Woodward p/n 8923-461) with seals and pins. Different connectors are available but not standard. Please contact the factory if you would like to use a different connector.

DETERMINING PROPER VALVE SIZEProper valve size can be determined by using the following equation:

Cv = Q * .00978 * (G * T / ((P1P2) * K)) ^ 0.5

Where:Q = Flow (PPH)G = Specic gravity of uid ( = 1.0 for air)T = Absolute temperature (460 + F)P1 = Inlet pressure (psia)P2 = Discharge pressure (psia)K = P2 if P1P2 is less than 10% of P1 = P1 if P1P2 is 25% or more of P1 = (P1+P2)/2 if P1P2 is in between 10 & 25%

P2 must be Greater than .53 * P1 (or ow becomes choked).

Cv (ow coefcient) should be calculated for the minimum and maximum ows expected (at 50) on the application.

Cv (Flow Coefcient)

COMMAND VS. POSITION FEEDBACK/THROTTLE POSITIONThe actuator is designed to provide 0.5 volts out-put at zero position, and 4.5 volts at full position. Feedback signals of 0 or 5 Vdc indicate faults.

The PWM input signal greater than 95% causes the output to go to zero position. Thus, if the PWM fails to 5 Vdc, the unit fails in a safe direction.

Temperature drift from 25 C to 105 C or from 25 C to 40 C causes the internal sensor to shift calibration. The effect of this is that the output position does not start to move until 0.8 Vdc and gets to the full position at 4.2 Vdc at 40 and 105 C. The output position signal will still track the command signal. This means that although the OEM cannot use this signal for true position, the OEM can still use this signal to verify that the Flo-Tech unit is responding to the command signal.

Cv for Standard Flo-Tech Units

Angle 33mm 48mm 60mm 68mm 75mm

0 0.689 1.36 1.81 2.44 1.41

5 0.787 1.81 2.57 3.04 3.37

10 1.30 3.34 4.65 4.83 2.71

15 2.70 6.64 9.39 10.4 8.28

20 4.63 10.8 15.9 18.3 16.9

25 6.86 16.0 24.0 28.1 28.3

30 9.58 21.8 33.1 39.7 41.8

35 12.7 28.5 43.7 53.4 57.8

40 16.3 36.2 55.9 70.0 76.2

45 20.4 45.0 70.4 88.0 97.3

50 24.9 54.8 86.8 109 120

55 30.1 65.9 105 133 147

60 33.8 75.6 125 157 174

65 35.9 81.6 138 179 200

70 36.1 82.9 151 197 220

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04140BFlo-Tech ITB Integrated Throttle Body and Actuator

CAUTION: Flo-Tech throttle body does not completely shut off. A separate shutdown is required.

Outline for Flo-Tech 75 mm Bore(Do not use for construction.)

Outline for Flo-Tech 33, 48, 60, and 68 mm Bores(Do not use for construction.)

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Ph: +1 (970) 962-7517 Fax: +1 (970) 962-7515


www.woodward.com





04140B

SPECIFICATIONS

Weight 6 kg (13.2 lbs)

Operating Temperature 40 to +105 C (40 to +221 F) Housing Temperature

Storage Temperature 55 to +105 C (67 to +221 F)

VibrationSine Sweep MS 810C, M514.2 Curve J (Mod)Random MS 202F, Method 214A, Cond. GTemp & Humidity SAE J1455


Flo-Tech ITB Integrated Throttle Body and Actuator

InputsPower Supply 9 to 32 Vdc (12/24 Vdc nominal) 10 A fuse in series with the input power. Must be able to supply 50 W for 0.25 second in transient conditions and 25 W continuous for steady state conditions.Position Using the max Cv number, and the chart below, Command select the Flo-Tech unit which most closely matches at 50 angle. Verify that the minimum required Cv is above the Flo-Tech units Cv ensuring the engine will reach idle when the Flo-Tech unit closes.

Input Command Input Range Input Impedance Other Commands

PWM 10-90% 117.4 kA PWM Frequency 5002000 Hz Amplitude 432 Vdc 10 bit resolution

0-5 Vdc 0.54.5 Vdc 152.7 kA

4-20 mA 519 mA 249 A

0-200 mA 20180 mA 35.7 A

Input Command Input Range Position Feedback Output 23 C

Position Feedback Outback 40 & 105 C

Nominal Actuator Range

PWM 1090% 0.54.5 0.1 Vdc 0.84.2 0.2 Vdc 070

0-5 Vdc 0.54.5 Vdc 0.54.5 0.1 Vdc 0.84.2 0.2 Vdc 070

4-20 mA 519 mA 0.54.5 0.1 Vdc 0.84.2 0.2 Vdc 070

0-200 mA 20180 mA 0.54.5 0.1 Vdc 0.84.2 0.2 Vdc 070

OU

TPU

TS

Valve Size (mm) Input Part No.

33 33 48 48 48 60 60

PWM4-20 mAPWM4-20 mA0-200 mAPWM0-5 Vdc

8235-1328235-1638235-1428235-1588235-1678235-1608235-157

PAR

T N

UM

BE

RS Valve Size (mm) Input Part No.

606868686875

4-20 mAPWM0-5 Vdc4-20 mA0-200 mAPWM

8235-1438235-1548235-1518235-2598235-1528235-140

PAGE | 32

APPLICATIONSThe ProAct ITB integrated actuator and throttle body is designed to throttle air or air/fuel for gaseous engines. This system is designed for direct replacement of traditional throttle valves, and requires no linkage between valve and actuator. The three sizes are designed to cover a wide range of engines and should be selected using the sizing procedure described inside this specication.

DESCRIPTIONThe PoAct Integrated Throttle Bodies (ProAct ITBs) are buttery valves electrically-actuated by ProAct Analog and ProAct Digital Plus actuators to control ow output. With bore sizes of 105 mm, 120 mm, and 135 mm, these ProAct ITBs are designed for use with engines in the 12 MW range. The ProAct actuators are electro-magnetic, 75 degree-of-travel devices, and therefore alleviate the problems associated with linkages on gas engines (such as setup, non-linearity, and wear).

This direct combination of throttle and actuator results in excellent stability and transient characteristics, and requires no hydraulics, pneumatics, or governor gear train. Therefore, you end up with an efcient, long lasting, and easily-installed throttle option.

ProAct ITB Integrated Actuator and Throttle Body for Large Bores (105, 120, 135 mm)


03305B

No linkage or couplings

Cost effective and highly efcient

Low maintenance

Requires no hydraulics, pneumatics, or governor gear train

Long lasting, easy to install throttle option

PAGE | 33


03305B

DETERMINING THE PROPER VALVE SIZEThe proper size valve can be determined us-ing the equation below. The required Cv (ow coefcient) should be calculated for both the minimum and maximum ows expected on the application. This design allows for a nominal travel of 75 degrees of rotation.

Using the graph and table below, select the closest valve that has a Cv equal to or greater than the calculated maximum ow value at approximately 80% opening (60 degrees) to ensure reasonable ow margin. Also, check that the particular valves minimum Cv listed below is less than the minimum calculated Cv for good low idle performance. For further assistance, consult the Woodward engineering department.

where:Cv = Flow CoefcientQ = Mass Flow (PPH [pounds/hour]) [1 pound = 0.45 kg]Sg = Specic Gravity of Gas (use 1.0 for air)T1 = Upstream Gas Temperature (F) [F = 1.8 * C +32]P1 = Inlet Pressure (psia) [1 psi = 6.895 kPa = 0.06895 bar]P2 = Downstream Pressure (psia)

Note: P2 must be greater than 0.528 * P1 or ow becomes choked. If P2 is less than 0.528 * P1, then use P2= 0.528 * P1.

Cv vs Angle for ProAct ITBs

Cv (Flow Coefcient)

Plate Angle 105 mm 120 mm 135 mm

0 1.04 1.09 1.10

5 7.53 8.68 11.51

15 26.37 30.42 40.67

25 58.74 68.96 93.33

35 97.05 127.28 172.75

45 156.83 215.44 292.46

55 244.65 350.02 471.51

65 369.57 563.30 782.29

75 509.52 810.50 1214.00


Cv := Q.0.00976

. (T + 460).P1.Sg

P1.Sg P1 P2

Note: These ow coefcients were determined using the test setup described in ANSI/ISA-S75.02-1996 Control Valve Capacity Test Procedure.

PAGE | 34


03305BProAct ITB Integrated Actuator and Throttle Body for Large Bores (105, 120, 135 mm)

ProAct ITB 105 with ProAct Digital Plus Model II(Also available with ProAct Analog.)(Do not use for construction.)

ProAct ITB 120 with ProAct Digital Plus Model II(Also available with ProAct Analog.) (Do not use for construction.)

PAGE | 35


Ph: +1 (970) 962-7517 Fax: +1 (970) 962-7515


www.woodward.com





03305B

SPECIFICATIONS

Operating Temperature RangeDigital Plus 40 to +85 C (40 to +185 F)Analog 40 to +74 C (40 to +165 F)Storage Temp Range 55 to +125 C (67 to +257 F) Vibration Qualication Woodward RV2 (0.1 G2/Hz Random, Test Spec 102000 Hz, 12.8 Grms 3 hours per axis) Shock Qualication 40 G, 11 ms sawtooth pulse Test Spec Weight See table under mounting section of manualNominal Diameter 135 mm (5.3 inches), 120 mm (4.7 inches), or 105 mm (4.1 inches)Maximum Working 60 psig (414 kPa/4.1 bar) Pressure

Technical Manual04166


ProAct ITB 135 with ProAct Digital Plus Model III(Do not use for construction.)

Regulatory ComplianceNote: Refer to the ProAct Digital Plus manual (26112) or ProAct Analog manual (26147) for actuator compliance. European Compliance for CE Marking:

Pressure Equipment Directive Certied to Pressure Equipment Directive 97/23/EC of 29 May 1997 on the approxi-mation of the laws of the Member States concerning pressure equipment, Category II

Other European Compliance:Compliance with the following European Directive does not qualify this product for application of the CE Marking:Machinery Directive Compliance as a component with 98/37/EC COUNCIL DIRECTIVE of 23 July 1998 on the approximation of the laws of the Member States relating to machinery.

52144

3800 NORTH WILSON AVENUE, LOVELAND, CO 80538

PH: +1 (970) 962-7517 FAX: +1 (970) 962-7515

WWW.WOODWARD.COM/SMARTFIRE WWW.WOODWARD.COM

Eric FeilerRTR

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