Manual CPC PDF

Installation and Operation Manual
CPC Current-to-Pressure Converter
Standard Version: 8901-457, 8901-459

[see manual 26248 for explosion-proof version]
Manual 89543D
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
WARNINGindicates a potentially hazardous situation which, if not avoided, could
result in death or serious injury.
CAUTIONindicates a potentially hazardous situation which, if not avoided, could

result in damage to equipment.
NOTEprovides other helpful information that does not fall under the warning or
caution categories.
RevisionsText 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 1996
All Rights Reserved
Manual 89543 CPC Current-to-Pressure Converter
Contents
CHAPTER 1. DESCRIPTION........................................................................... 1
Introduction.............................................................................................................1
Construction ...........................................................................................................2
CHAPTER 2. SPECIFICATIONS ...................................................................... 6
Electrical Specifications..........................................................................................6
Hydraulic Specifications .........................................................................................6
Performance ...........................................................................................................7
Environmental.........................................................................................................8
Physical ..................................................................................................................8
Default Factory Settings .........................................................................................8
CHAPTER 3. INSTALLATION.......................................................................... 9
Receiving Instructions ............................................................................................9
Unpacking Instructions ...........................................................................................9
Mounting Instructions .............................................................................................9
Electrical Connections..........................................................................................11
CHAPTER 4. CALIBRATION......................................................................... 15
Introduction...........................................................................................................15
Checkout ..............................................................................................................15
Calibration ............................................................................................................19
CHAPTER 5. REPAIR INSTRUCTIONS........................................................... 22
General .................................................................................................................22
Return for Repair Instruction ................................................................................22
Protective Packaging............................................................................................22
Troubleshooting....................................................................................................22
CHAPTER 6. SERVICE OPTIONS ................................................................. 25
Product Service Options.......................................................................................25
Returning Equipment for Repair...........................................................................26
Replacement Parts ...............................................................................................27
How to Contact Woodward...................................................................................27
Engineering Services ...........................................................................................28
Technical Assistance............................................................................................29
APPENDIX A. MANUFACTURERS DECLARATION OF CONFORMITY ............... 30
Woodward i
CPC Current-to-Pressure Converter Manual 89543
Illustrations and Tables
Figure 1-1. Front View of the CPC .........................................................................1

Figure 1-2. Hydraulic Schematic ............................................................................1
Figure 1-3. Functional Block Diagram (CPC electronics) ......................................3
Figure 1-4. CPC Cross Section ..............................................................................4
Figure 2-1. Flow Characteristics.............................................................................7
Figure 3-1. Obsolete I/H Converters ....................................................................10
Figure 3-2. New CPC with I/H Adapter Block.......................................................10
Figure 3-3. Mounting the CPC..............................................................................11
Figure 3-4. CPC Outline Drawing.........................................................................12
Figure 3-5. Woodward Adapter Plate ...................................................................13
Figure 3-6. I/H to CPC Adapter Plate ...................................................................14
Figure 4-1. PCB Component Location .................................................................16
Figure 4-2. Output Pressure vs. Command Input ................................................17
Figure 5-1. Removing the CPC Filter ...................................................................24
Table 4-1. CPC Wiring..........................................................................................16
ii Woodward
Chapter 1.
Description
Introduction
The Woodward CPC (Current-to-Pressure Converter) is intended for positioning
steam and/or fuel valves and/or associated servo systems. The CPC supplies a
hydraulic fluid output pressure proportional to the 420 mA input current signal.
Apart from accurate pressure control, the CPC is designed for easy mounting
and servicing. The flat surface with three hydraulic connections mounts to an
adapter plate with the actual hydraulic fittings. This plate remains a part of the
installation when removing the CPC, for example, during flushing of the lines
when commissioning the installation.
Figure 1-1. Front View of the CPC
The customers cable enters the CPC via a cable gland. Unscrewing the cap
reveals the easy-to-access printed circuit board. The wires are connected to
board-mounted terminals. Two sets of potentiometers on the board allow
calibration and dynamic settings.
Figure 1-2. Hydraulic Schematic

Woodward 1
Construction
The CPC consists of the following main parts:
Housing
Hydraulic valve
Actuator
Printed circuit board
Pressure sensor
Housing
The housing is a cast-aluminum, black anodized block, supporting all other parts.
It contains the hydraulic ports and the mounting holes on one side of the square
section and the cable gland on the other.
Together with the aluminum cover, the flameproof enclosure contains the
electronics, the actuator, and the pressure sensor.
The spiral return spring is installed on the base and protected by a cover.
The entire CPC construction is water- and dust-proof, in accordance with class
IP65.
Hydraulic Valve
An innovative hydraulic valve controls the oil flow from supply to output port, or
from output to tank. (see Figure 1-2). The valve consists of a steel bushing in
which a steel plunger moves. The special construction ensures proper, reliable,
and contaminant-tolerant operation, using standard lube oil.
Actuator
The CPC uses a Woodward-developed, rotary limited angle torque (LAT)
actuator. It is a type of stepping motor with steps of 90 degrees, operated using a
mini-stepping technique in one quadrant. The rotating angle is mechanically
limited to 22.5. The rotor, with the permanent magnet, is directly coupled to the
hydraulic valve. The current signal to the coils is generated by the driver circuit of
the electronics.
Printed Circuit Board

The printed circuit board is mounted on top of the housing (see Figure 1-3). The
printed circuit board performs the following tasks:
Power supply
Signal conditioning of input and output signals
PID output loop for output pressure
PID output loop for valve position
Actuator driver
Current limiting
Fault detection
Dither generation
2 Woodward
The power supply section performs the EMI filtering on the 1832 Vdc input
voltage and generates an internal +10 Vdc. The internal voltage powers the
circuit. The filtered input voltage is used to power the pressure sensor and the
actuator driver.
Figure 1-3. Functional Block Diagram (CPC electronics)
Each input and output signal from the printed circuit board is EMI protected.
The 420 mA pressure signal from the internal pressure transmitter is

transformed into a voltage signal. The Pressure Level and Pressure Range
potentiometers tune this signal for the specified output pressure range.
The 420 mA input signal gives a 15 Vdc signal via a 250 resistance.
A relay provides a discrete contact for fault detection. A red lamp will light when
the relay is active. The drive signal is monitored, and is detected when it exceeds
its range for longer than two seconds. This indicates that the required level of
output pressure is either too high or too low. When this occurs, the relay will
change state. Set jumper to either JPR1 or JPR2. JPR1 gives a normally-open
alarm, and JPR2 gives a normally-closed alarm.
The Signal Range potentiometer adjusts the current output signal so that the
minimum and maximum pressures correspond with 4 and 20 mA respectively.
The actual valve position is measured by a non-contacting position sensor,

integrated into the board.
The pressure output loop, with adjustable gain and stability, generates a valve
position reference signal for the valve position output loop, depending on the
pressure reference signal and measured pressure signal. The dynamic settings
can be adjusted to match the characteristics of the controlled servo system.
The driver provides the actuator with a high-current, pulse-width-modulated

(PWM) signal, depending on the drive demand signal.
Woodward 3
The current passing through the actuator is monitored. It can go up to 5 A for a
period of three seconds, boosting the torque of the actuator to its maximum.
Then the current is limited to approximately 1.5 A, in order to protect the circuitry.
The drive demand signal checks that the CPC is functioning correctly. When the
signal exceeds its normal operating window for longer than two seconds, the
CPC is presumably unable to maintain the required pressure level, and the relay
will change state. A red lamp indicates when the alarm relay is active
A dither signal can be superimposed on the drive signal. The amplitude and
frequency can be adjusted. The dither signal is intended to give a relatively high
frequency ripple on the output pressure. It can be used to reduce the effect of
static friction in the CPC and the attached servo system.
Pressure Sensor
The pressure sensor is a two-wire 420 mA transmitter (with a third wire for
shielding purposes).
When the CPC is supplied with hydraulic and electric power, and a current input
signal between 4 and 20 mA, it will output a certain pressure within the factory
set pressure range. The operation is as follows. See also Figures 1-3 and 1-4.
Figure 1-4. CPC Cross Section
4 Woodward
1. The pressure reference and actual pressure signals are compared by the
pressure output loop, and generate a reference valve position signal.
2. The valve position is measured with a board-mounted sensor. The position

signal, together with the valve position reference, is used by the position
output loop with fixed dynamics. This provides a fast and stable valve
position output.
3. The output loop outputs a drive signal. The driver generates the correct
PWM high current signal to the actuator, which results in the valve position
as required.
4. The hydraulic valve has two ports: Supply to Output and Output to Tank. The
three hydraulic connections are indicated on the CPC.
5. With the hydraulic valve in its mid position, both ports are closed, and
assuming no leakage is present, the output or output pressure is maintained
at its level.
6. The output pressure is measured by the pressure transmitter. When either

the output pressure or the pressure reference changes, it is detected by the
electronics. As previously described, the valve position will change.
7. For an increase in output pressure, the change will result in an opening of

the Supply to Output port, resulting in a flow from high pressure oil to the
output port. For a decrease in pressure the Output to Tank port will be
opened, allowing the oil to flow from the servo system to the tank.
8. With leakage of the servo system, the valve will always open the Supply to
Output connection to a certain extent to maintain the output pressure.
9. A small difference in desired and actual valve position will cause the position
output loop to integrate to one of the extremes, thus assuring that the full
actuator force is available for changing position.
10. Should this not result in the correct match of pressure reference and
measured pressure, the electronics will detect that the valve position
requirement has been extreme. After two seconds, the relay will change
state, giving an external signal of a failing pressure output.
11. A return spring forces the valve to open the Output to Tank port on loss of
power. This assures a fail-safe operation.
Woodward 5
Chapter 2.
Specifications
Electrical Specifications
Connections 9 terminals on the internal printed circuit board
suitable for 0.54 mm solid or 0.52.5 mm
stranded wire (2212 AWG)
Cable Entry via cable gland. Cable dia. 10.513 mm
Supply Voltage 1832 Vdc (24 Vdc nominal) (use cable at least
1.5 mm/16 AWG)
Power Consumption 8 W during steady state, 48 W maximum, 120 W
peak (3 s maximum)
Current Input Signal 420 mA into 250 . CMRR max. 20 Vdc
Analog Output Signal 420 mA. Maximum external load: 300
Accuracy 1% of full scale
Discrete Output Signal Relay, jumper selectable for NO or NC, 100 000
operations
1.0 A at 30 Vdc, max. 33 Vdc
0.75 A inductive at 28 Vdc 0.2 henry
Dither Frequency 1030 Hz. Default setting is 30 Hz
Dither Amplitude Zero is minimum and default. Maximum
depends on adjusted frequency and dynamic
characteristics of the entire system.
Hydraulic Specifications
Connections Flat mounting face with 3 holes. See Figure 3-4
for hydraulic connections, and Figures 3-5 or 3-6
for mounting via an adapter plate (optional).
Supply Pressure 17 bar (250 psi) maximum. At least 0.5 bar
higher than the maximum output pressure.
Tank Pressure At least 0.5 bar lower than the minimum output
pressure.
Output Pressure Min. level: 1 bar (14.5 psi), max. level: 15 bar
(217.5 psi)
Min. range: 1 bar (14.5 psi), max. range: 14 bar
(203 psi)
Recommended Filter Rating 40 m nominal, 75 m absolute or better. (40 =
75 or better).
Viscosity 20 to 100 cSt
Leakage Depends on viscosity and supply pressure. See
Figure 2-1.
Flow Capacity Depends on viscosity and pressure difference.
See Figure 2-1. Reverse flow is 30-50% greater
than forward flow, due to a filter inside the CPC
at supply input.
6 Woodward
Figure 2-1. Flow Characteristics
Performance
Frequency Response 1030 ms, time constant at small step, blocked
load (no servo systems connected to the
CPC).Time constant 30300 ms with a total
settle time of 100500 ms if the hydraulic load
has a time constant of up to two seconds.
Ultimate dynamic response depends on total
servo system and dynamic adjustments of the
CPC.
Linearity 0.2% of full range
Hysteresis 0.1% of full range
Repeatability 0.1% of full range
Temperature Drift < 0.01% full range / C
Woodward 7
Environmental
Ambient Temperature 20 to +85 C
Humidity 95% relative humidity
Oil Temperature Continuously 60 C max. Peak 80 C (23 days)
Max. Surface Temperature 85 C
Vibration Lloyds LR type approval test spec. 1 and 2
(5100 Hz at 4G)
EMC EN 50 081-2 and EN 50 082-2. Compliance with
CE mark immunity and emissions requirements
for heavy industry environments.
Water and Dust Proof IP-65
Physical
See also Figure 3-4, CPC Outline Drawing.
Height x Width x Depth Approx. 220 x 170 x 170 mm (8.7 x 6.7 x 6.7
inch)
Weight Approx. 10 kg without oil
Mounting Four M10 threaded holes, 2024 mm deep, on
the face with the hydraulic ports
Default Factory Settings

Gain = 30% (1 turn potentiometer)
Stability = 30% (1 turn potentiometer)
Dither Amplitude = 0% (1 turn potentiometer)
Dither Frequency = 30 Hz (1 turn potentiometer)
Output Pressure Range = 1.54.5 bar (420 mA)
8 Woodward
Chapter 3.
Installation
Receiving Instructions
The CPC is carefully packed at the factory to protect it from damage during
shipment. However, careless handling during shipment can result in damage.
Notify the shipping company if damage is found.
Unpacking Instructions
Carefully unpack the CPC and remove it from the shipping container. Do not
remove the shipping plate or plugs, until ready to mount.
Mounting Instructions
Location Considerations
When selecting a location for the CPC, consider the following:
Provide adequate ventilation and avoid placing or attaching the CPC to heat
generating or conducting parts of the installation.
Locate the CPC as close as possible to the servo: short hydraulic lines (and
volume) help to achieve optimum response.
Avoid mounting the CPC at places with excessive vibration.
Mounting the CPC

(Figure 3-3)
The CPC is designed for vertical or horizontal mounting.
The CPC mounts to an adapter block (or plate). The adapter block connects the
three hydraulic CPC ports with the external oil supply, turbine drain, and control-
output of the steam valve servo. The CPC is attached (clamped) to the adapter
block by M10 screws. The screws should screw into the CPC a minimum of 20
mm for a reliable and solid mounting.
Construction should allow easy removal and re-connection of the CPC by just
loosening or fastening the M10 bolts.
Allow space for removal of the cover, to gain access to the adjustments on the
printed circuit board.
Place the CPC against the adapter plate with the gasket in between and secure it
with M10 screws and appropriate locking devices. Be sure that the hydraulic
ports correspond with their designation. Optionally, Woodward can provide a
mounting plate. This plate is made of steel (see Figure 3-5). These plates can be
joined to the turbine frame using two M12 screws or can be welded in place.
Woodward 9
Hydraulic Connections
Three hydraulic lines must be connected to the adapter block (or plate; see
Figure 3-3):
S (supply)Left
O (Output)Center
T (Tank)Right
S, O and T are marked on the CPC.
The pipe inner diameters should be large enough to prevent excessive pressure
loss during transient flow conditions. A minimum inner diameter of 12 mm is
required.
The CPC needs to be installed correctly. The pump capacity and/or associated
accumulators needs to be large enough for the required slew rate of the attached
servo system.
Before installing the CPC, the hydraulic lines, supply, tank, and the line from
CPC to the controlled servo system, should be thoroughly flushed.
I/H to CPC Special Mounting Adapter

A special mounting pad is available to exchange the CPCs predecessor, the I/H
converter, with a CPC. See Figures 3-1 and 3-2.
Figure 3-1. Obsolete I/H Converters

(European design, left; US design, right)
Figure 3-2. New CPC with I/H Adapter Block

(existing hydraulic tubing left in place)
10 Woodward
Electrical Connections
Follow local and national procedures, codes, and directives for installing
electrical/electronic equipment. The electrical power supply should be able to
output 2 A at 24 Vdc continuously, with a peak of 5 A during three seconds.
The CPC has one cable entry, for cable sizes between 10.5 and 13 mm. The
cable isolation must have a temperature rating of more than 80 C continuous.
1. Strip the cable isolation (not the wire isolation) 12 cm down. Strip the wire
isolation 5 mm down. Mark the wires according to their designation and
install connectors, if required.
2. Remove the clamp screw and the rubber grommet of the cable gland and
slide them over the wires in the correct order, until the grommet is at the end
of the cable isolation.
3. Remove the CPC cover. Move the wires through the cable gland and up to
the printed circuit board.
4. Re-install and tighten the clamp screw. The Teflon tube provided with the
CPC can be used to protect the wires inside the CPC.
5. Connect the wires to the terminals on the printed circuit board. The terminals
accepts wires as specified in the Electrical Specifications in Chapter 2. A
wire size of 1 mm or 18 AWG is recommended for signals. A size of 1.5
mm is recommended for power. The terminal designations are shown in
Table 4-1. Terminals 10 to 13 are pre wired at the Woodward factory and
should not be changed.
6. Secure the cable outside the CPC to prevent pull forces on the cable gland.
Figure 3-3. Mounting the CPC
Woodward 11
Figure 3-4. CPC Outline Drawing
12 Woodward
Figure 3-5. Woodward Adapter Plate
Woodward 13
NOTE
The Woodward I/H converter is obsolete. It can easily be replaced by the
CPC using Woodward adapter plate 3689-097.
Figure 3-6. I/H to CPC Adapter Plate
14 Woodward
Chapter 4.
Calibration
Introduction
After installation, the CPC must be checked for proper operation and calibration
before use. The factory has conducted a functional test. Final checkout and
customer calibration must be completed after installation. For default factory
settings, see Chapter 2.
WARNING
Read this entire manual and all other publications pertaining to the work to
be performed before installing, operating, or servicing of 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 (overtemperature, or overpressure, where applicable)
shutdown device(s), that operates totally independently of the prime mover
control device(s) to protect against runaway or damage to the engine,
turbine, or other type of prime mover with possible personal injury or loss of
life should the mechanical-hydraulic governor(s) or electric control(s), the
actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or the
controlled device(s) fail.
Checkout
A checkout of the CPC is done to verify proper installation, wiring, and
connection of the hydraulic lines.
NOTE
The checkout procedure will verify correct installation. This procedure is a
bench test of the CPC.
The checkout procedure cannot be run, if the prime mover is powered up.
Woodward 15
Figure 4-1. PCB Component Location
Table 4-1. CPC Wiring
Wiring List of Terminal Block 2 (for customer)

Pin 1 and 2 + 24 Vdc Power Supply
Pin 3 Ground (Shield, if used)
Pin 4 and 5 + 420 mA Input Signal
Pin 6 and 7 + 420 mA Output Signal
Pin 8 and 9 Relay Output Signal
Terminal Block 1 (factory connected)
Pin 10 Actuator (Yellow)
Pin 11 Actuator (Green)
Pin 12 Pressure Sensor (White)
Pin 13 Pressure Sensor (Grey)
To shield via screw (only Pressure Sensor (Black)
standard version)
Jumper Setting
JPR1 Connected NO
JPR2 Connected NC (factory set)
Explanation of Adjustments and Test points

Seven adjustments can be made, and 14 test points have been provided. The
adjustments are explained below. See Figure 4-1 for the location of the
potentiometers and test points (TPs). For default factory settings, see Chapter 2.
16 Woodward
Pressure Level This adjustment sets the level of output pressure.
Adjusting the level changes all points of the output
pressure uniformly. Adjusting clockwise increases the
level. See Figure 4-2.
Pressure Range This adjustment sets the slope of the output pressure.
Adjusting clockwise increases the amount of slope of the
line. See Figure 4-2.
Figure 4-2. Output Pressure vs. Command Input
Gain This adjustment sets the amount of gain (proportional

action) for the pressure control circuit. In most cases,
50% gain can be used. High gain provides a fast
response time, but can cause instability.
Stability This adjustment sets the stability (integration action) of

the controller circuit. The stability cooperates with the
Gain setting to provide stable operation. Adjusting
clockwise increases the stability.
Dither Amplitude This adjustment sets the amplitude of the output dither.
Dither is used to keep the hydraulic part of the CPC and
attached servo systems from sticking, if necessary. The
amplitude should be kept at a minimum to prevent
objectionable oscillation. It is factory set to zero.
Adjusting clockwise increases dither amplitude.
Dither Frequency This adjustment sets the frequency of the dither. It can
be changed to accommodate different servo systems. It
is factory set to maximum (~30 Hz). Adjusting
counterclockwise decreases the frequency.
Woodward 17
Signal Range This adjustment sets the range of the 420 mA output
signal. The level is fixed.
Relay Jumper Using a jumper, the relay contact can be set to normally
open (NO) or normally closed (NC).
The printed circuit board is provided with 14 test points (for use only by
Woodward personnel). The voltages, measured at those test points, represent
the following signals:
TP1 Alarm
TP2 Pressure (1.57.5 V)
TP3 Error Signal (5 V = no error)
TP4 Position
TP5 Correct Position
TP6 Drive Signal (desired current through the core)
TP7 23 V (1823 V)
TP8 420 mA input signal, 4 mA = 8.5 V, 20 mA = 2.5 V
TP9 Internal Power Supply (+10 V)
TP10 Ref. 5 V
TP11 GND internal CPC (not the same as +24 V GND)
TP12 Triangle Wave Signal
TP13 PWM Signal to Driver
TP14 Current through Coil, 6 V = +0.83 A, 5 V = 0 A, 4 V = 0.83 A
Set-up/Checkout Procedure
1. Verify that the correct hydraulic and electrical connections are complete,
according to chapter 3.
2. Confirm that the hydraulic and electrical power to the CPC is turned off.
3. Remove the top cover of the CPC.
4. Connect a calibrated pressure gauge to the control output line, in order to

measure output pressure.
5. Connect a mA current source with a current meter, in series, to terminals 4

(+) and 5 ().
WARNING
To prevent personal injury or death and damage to equipment, the
controlled device must not be allowed to run or operate during this
procedure. The main steam valve or main fuel control must be turned off to
prevent operation of the controlled device.
6. Apply electrical power to the CPC. The green LED will illuminate.
7. Check the power supply by measuring the voltage at terminal 1 and 2.
8. Check internal power supply at test pins TP9 and TP11. The reading should
be +10 0.1 Vdc.
9. Start the hydraulic supply system and turn the current source on. Check that
the oil is up to operating temperature and that all air has been purged from
the system. The air can be purged by adjusting the current input signal up
and down several times. Allow for warm-up time.
18 Woodward
10. Observe the pressure gauge when changing the current input signal. The
pressure level should correspond with the default values specified in Chapter
2.
Calibration
This section covers calibration and other electrical adjustments of the CPC.
Refer to Figure 4-1 for the location of the different potentiometers.
Output Pressure vs. Command Input

1. Set the current source to 12 mA and measure the output pressure.
2. Adjust the Pressure Level for the desired output pressure.
3. Adjust the current source to 20 mA and measure the output pressure.
4. Adjust the Pressure Range for the desired output pressure.
5. Check the 12 mA setting again, and adjust the level if necessary.
6. Check the 4 mA setting again, and adjust the output with range if necessary.
Note that turning the range clockwise results in a decrease of pressure.
7. Repeat steps 1 through 6 until the output pressures at both extremes fall in
the desired tolerance.
NOTE
The pressure level and pressure range adjustments are 25-turn
potentiometers.
Dynamic Adjustments
1. Adjust the current source to 12 mA.
2. Adjust the Gain slowly clockwise to the middle position. If the controlled
output pressure becomes unstable, adjust the Gain counterclockwise.
Normally 50% gain can be used for all types of loads.
3. Turn the Gain counterclockwise for small servo volumes, and clockwise for
bigger servo volumes.
4. Use 1020% stability for a small or blocked servo. Use 5060% for a bigger
servo, with about two seconds time constant. Increase the stability further if
the oil is cold or has a high viscosity.
5. If high frequency oscillations are observed, the Stability can be decreased.

Decreasing the Stability normally results in the possibility to further increase
the Gain.
6. Check the stability over the full range by adjusting the input current between
4 and 20 mA in small stepwise changes.
Woodward 19
Output Current Signal

This signal is factory calibrated. If needed, re-adjust as follows:
1. Connect a current meter to terminals 6 (+) and 7 (). Set the input current
source to 12 mA and measure the output current signal.
2. Adjust the Signal Range until the output signal is 12 mA.
3. Adjust the current source to 4 and 20 mA and measure the output current
signal.
4. Adjust the Signal Range until both the 4 and 20 mA fall within 1% accuracy.
The level is fixed to 0 mA.
Discrete Output Signal

The jumper setting for a NO or NC contact is shown in Figure 4-1. When an error
condition is present, such as incorrect pressure or incorrect position at the
internal valve, the relay will switch and the red lamp will illuminate. This major
alarm has a set and reset time of two seconds. A non-resettable function of the
relay can be achieved by adding an external relay circuit.
Dither
The dither can be adjusted while the prime mover is operating. Beware of
unacceptable oscillations when introducing dither. It is recommended to always
use some dither.
1. Turn the Dither Amplitude clockwise to increase the amplitude until

oscillation of the output pressure or valve position can be observed.
Decrease the amplitude slightly to prevent objectionable wear in the system.
2. If the frequency is too high for the attached servo system, reduce it by
turning the Dither Frequency counterclockwise.
Due to the dynamic characteristics of the CPC, the amplitude of the pressure
fluctuations will normally increase when reducing the frequency.
Finish Checkout
1. Turn off the milliamp source.
2. Remove the milliamp current source and (re)connect the plant wiring.
3. Remove additional current and/or voltmeters and (re)connect the plant

wiring.
4. If applicable, remove the pressure gauge from the control output hydraulic
line.
5. Re-install the cover.
20 Woodward
The CPC is now ready for normal operation.
WARNING
To protect against personal injury, loss of life, and/or property damage when
starting the engine, turbine, or other type of prime mover, be prepared to
make an emergency shutdown to protect against runaway or overspeed
should the mechanical-hydraulic governor, or electric control; the driving
mechanism, the linkage, or the controlled device fail.
Woodward 21
Chapter 5.
Repair Instructions
General
Repairs and servicing of the CPC must be performed by Woodward or its
authorized service facilities.
Removal or vandalism of the nameplate is prohibited.
Return for Repair Instruction

Should the CPC need to be returned for repair, attach a tag on the unit. Include
the following information on the tag:
Customer's name and address
The name and location where the equipment is installed
Complete Woodward part number and serial number
Description of the failure
Instructions as to what type of repair is to be done
Protective Packaging
The following procedures are used for protective packaging of the CPC, if
returning for repair:
1. Install shipping plates or plugs in all hydraulic connection ports or seal with
tape.
2. Wrap the CPC with packaging materials that will not damage the surface of
the unit.
3. Place in a double-walled packing carton.
4. Place at least 10 cm of tightly packed, industry-approved, shock-absorbing
material around the unit.
5. Secure the carton with strong tape around the outside of the carton to
increase the strength of the carton.
Troubleshooting
General
The following troubleshooting guide will help you isolate trouble with the control
circuit board, actuator, wiring, or elsewhere. Troubleshooting beyond this level is
recommended ONLY when a complete facility for control testing is available.
The wrong voltage can damage the control. When replacing a control, check the
power source and wiring connections for the correct voltage.
22 Woodward
Troubleshooting Procedure
This table is a general guide for isolating system problems. Before using the
guide, make sure that the system wiring contacts and input/output connections
are correct and in good working order. Complete the checks in order. Each
check assumes that the preceding checks have been completed and any
problems have been corrected.
WARNING
To protect against personal injury, loss of life, and/or property damage when
starting the engine, turbine, or other type of prime mover, be prepared to
make an emergency shutdown to protect against runaway or overspeed
should the mechanical-hydraulic governor, or electric control; the driving
mechanism, the linkage, or the controlled device fail.
Problem Cause Remedy

No pressure out. Faulty power, check green lamp. Check power connections, 24 Vdc at
pins 1 and 2 (pin 1 should be +).
Error condition, check red lamp If on: Check actuator wire connection.
(= alarm = discrete output is If off: Check pressure sensor
active). wires.
Power supply too weak. Change power supply. See
specification.
Power supply is limiting current. Change limit level to maximum (>= 5
A).
Bad power supply. Use Woodward recommended power
supply.
Full pressure out. Pressure sensor connected Check wire connections (Table 4-1).
incorrectly.
Other faulty wiring. Check wire connections (Table 4-1).
Slow dynamics. Filter not clean. Clean filter (see Figure 5-1).
Dynamic adjustments not Raise Stability, and maybe Gain.
optimal.
Cold oil (viscosity too high). Wait until normal temperature is
reached or change dynamic
adjustments (raise Stability).
Tubes too small or too long. Use bigger and/or shorter tubes.
Water in oil. Clean or change the oil.
High-frequency Servo is outside its working Nothingthis is normal.
oscillation. range.
Oil viscosity changed. Re-adjust dynamics or reduce dither.
Faulty valve position feedback. Contact Woodward service.
Low-frequency High friction in servo. Change dither amplitude and
oscillation. frequency.
Abnormal high friction in servo. Clean or change servo piston.
Low CPC internal friction. Change dither amplitude and
frequency.
High CPC internal friction. Contact Woodward service.
Alarm not working. Is the red lamp on? If yesCheck the jumper. It must be
set!
If noCheck the pressure range.
See specifications.
420 mA output not Incorrectly calibrated. Adjust the output. See calibration.
working.
Woodward 23
Problem Cause Remedy

Occasional Wires broken. Replace faulty wire(s).
disturbance. Wire protection broken. Replace faulty wire(s).
Wire protection broken inside the Check pressure sensor and actuator.
CPC.
Bad contact at connectors. Re-install all wires.
Too high ambient or oil Lower temperature. See specification.
temperature.
Leaking inside Pressure sensor is loose. Fasten the pressure sensor. Check O-
CPC. ring.
Other reasons. Contact Woodward service.
Large pressure Abnormal high friction in servo. Clean or change servo piston.
hysteresis. Abnormal high internal friction. Contact Woodward service.
Non-zero pressure Return spring is broken. Replace the return spring.
at power off. Tank pressure is too high. Reduce tank pressure.
Figure 5-1. Removing the CPC Filter
24 Woodward
Chapter 6.
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 25
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.
26 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 Woodwards website (www.woodward.com) for the
name of your nearest Woodward distributor or service facility.
Woodward 27
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
Emailicinfo@woodward.com
Websitewww.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.
28 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 29
Appendix A.
Manufacturers Declaration of Conformity
Product Identification
Product: CPC
Application: Current-to-Pressure Converter for prime mover control
Manufacturer: Woodward Governor Nederland BV
Type: Part numbers 8901-457/-459
Means Of Conformity
The product is in conformity with Directive 89/336/EEC based on test results
using harmonized standards in accordance with Article 10.1 of the Directive.
Testing
Carried out at : Darell Electronics, Woerden, The Netherlands
NMi Certin B.V., Delft, The Netherlands
Woodward Governor Company, Loveland, USA
Standards used : EN 50081-1:1991

EN 50082-2:1994
Test Reports : XN 165-R1
XN165-R25
XN 165-R29
Manufacturer
Company : Woodward Governor Nederland B.V.
Hoofdweg 601
2131 BA Hoofddorp
The Netherlands
Representative : Mr. T. Lloyd, Plant Manager
Date : January 1997
30 Woodward
We appreciate your comments about the content of our publications.
Send comments to: icinfo@woodward.com
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 Websitewww.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

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Installation and Operation Manual

CPC Current-to-Pressure Converter

Standard Version: 8901-457, 8901-459

Electronic controls contain static-sensitive parts. Observe the following

CAUTIONindicates a potentially hazardous situation which, if not avoided, could

RevisionsText changes are indicated by a black line alongside the text.

Illustrations and Tables

Figure 1-1. Front View of the CPC .........................................................................1

Table 4-1. CPC Wiring..........................................................................................16

Figure 1-1. Front View of the CPC

Figure 1-2. Hydraulic Schematic

Printed Circuit Board

Figure 1-3. Functional Block Diagram (CPC electronics)

The 420 mA pressure signal from the internal pressure transmitter is

The actual valve position is measured by a non-contacting position sensor,

The driver provides the actuator with a high-current, pulse-width-modulated

Figure 1-4. CPC Cross Section

2. The valve position is measured with a board-mounted sensor. The position

6. The output pressure is measured by the pressure transmitter. When either

7. For an increase in output pressure, the change will result in an opening of

Figure 2-1. Flow Characteristics

Water and Dust Proof IP-65

Default Factory Settings

Mounting the CPC

The CPC is designed for vertical or horizontal mounting.

I/H to CPC Special Mounting Adapter

Figure 3-1. Obsolete I/H Converters

Figure 3-2. New CPC with I/H Adapter Block

Figure 3-3. Mounting the CPC

Figure 3-4. CPC Outline Drawing

Figure 3-5. Woodward Adapter Plate

Figure 3-6. I/H to CPC Adapter Plate

Figure 4-1. PCB Component Location

Table 4-1. CPC Wiring

Wiring List of Terminal Block 2 (for customer)

Explanation of Adjustments and Test points

Figure 4-2. Output Pressure vs. Command Input

Gain This adjustment sets the amount of gain (proportional

Stability This adjustment sets the stability (integration action) of

3. Remove the top cover of the CPC.

4. Connect a calibrated pressure gauge to the control output line, in order to

5. Connect a mA current source with a current meter, in series, to terminals 4

7. Check the power supply by measuring the voltage at terminal 1 and 2.

Output Pressure vs. Command Input

2. Adjust the Pressure Level for the desired output pressure.

3. Adjust the current source to 20 mA and measure the output pressure.

4. Adjust the Pressure Range for the desired output pressure.

5. Check the 12 mA setting again, and adjust the level if necessary.

5. If high frequency oscillations are observed, the Stability can be decreased.

Output Current Signal

2. Adjust the Signal Range until the output signal is 12 mA.

The level is fixed to 0 mA.

Discrete Output Signal

1. Turn the Dither Amplitude clockwise to increase the amplitude until

3. Remove additional current and/or voltmeters and (re)connect the plant

5. Re-install the cover.

Removal or vandalism of the nameplate is prohibited.

Return for Repair Instruction

Problem Cause Remedy