CPC-II

Current-to-Pressure Converter

Applications

The CPC-II (current to pressure

converter, generation II) is an

electrohydraulic pressure-regulating

valve control designed for use in

positioning single-acting steam turbine

valve servos. This CPC’s superb

accuracy and resolution make it ideal

for steam turbine valve control and

related turbine speed and load

control. The CPC accepts a 4–20 mA

pressure demand signal and

accurately controls oil pressure to

precisely position single-acting steam

turbine governor-valves. Precise and

stable steam valve control directly

relates to improved steam turbine

speed and load control and reduced

system mechanical wear.

The CPC’s redundancy features make it ideal for critical steam turbine applications,

where turbine up-time and availability are essential. This converter can be configured to

accept redundant pressure demand inputs, from one or two (redundant) controllers, and

vote the input to follow. Alternatively the CPC can be configured to accept signals from

both its internal oil pressure sensor and an external (redundant) oil pressure sensor, and

use the voted healthy signal.

The CPC’s robust design (strong actuator, corrosion-resistant material, single moving

rotary valve, and self-cleaning port design) makes it ideal for challenging applications

where dirty or contaminated oil may be present.

• Oil contamination

resistant

• Precise fluid

pressure control

• Stable & linear valve

control

• Included valve

linearization table

• Redundant

inputs/sensors for

critical applications

• Accepts signals

from redundant

controllers

• Redundant (dual)

CPCs

(Master/Slave)

functionality

• Standard mounting

and hydraulic

connections

• Self cleaning valve

algorithm

• Status & health

indication

CPC-II

Optionally two controllers can be connected to a single CPC in a redundant Master/Slave

fashion to allow the turbine to continue to operate if either turbine control fails, or on-line

changes are desired. Designed for use in applications requiring full redundancy,

optionally two CPCs can be applied in a dual-redundant fashion, simplifying the entire

system and control wiring.

Description

The CPC is an electrohydraulic pressure-regulating valve control that utilizes a very

accurate internal pressure sensor and PID controller to precisely control steam turbine

valves. The CPC consists of a valve-actuator assembly, pressure sensor, and electronic

driver module. The unit’s driver module accepts one (or two) 4–20 mA pressure setpoints

and compares these setpoints to the sensed oil pressure, to accurately control turbine

valve oil pressure.

The CPC controls oil pressure by porting supply-oil to its control-oil output port (turbine

valve control oil) or back to the system supply tank. This converter’s special PID

architecture allows it to perform very stable pressure control during normal conditions,

and respond in milliseconds to desired valve step changes during system or plant

transients. As a means of protecting the turbine, an internal valve-return-spring forces the

CPC to a failsafe position (port oil to drain) and safely close turbine control valves upon

any internal unit failure (electrical input power failure, pressure sensor failure, processor

failure, etc.).

CPC-II

The CPC is factory and/or field configurable via a computer

based service tool. The CPC’s PCI Service Tool uses a simple

user-friendly format to allow users to easily configure,

calibrate, and adjust all internal functions and PID control

settings. The CPC includes a 4–20 mA output channel to

indicate control oil pressure level, and unit alarm and shutdown

relay outputs for use as unit health and status indications into

the system controller or plant DCS.

A Manual Stroke function allows users to manually stroke the

CPC output pressure (turbine valve position) locally at the

unit, via an internal Manual Stroke Screw. This local manual

stroke function is designed with built in security logic to

protect the users from un-intentional use of this function

during normal operation. Manual Stroke capability is also

available via remotely or locally via the CPC’s computer

based PCI Tool.

Since flow through single and staged inlet steam valves tend

to be non-linear throughout their flow range, turbine controls

are typically de-tuned to compensate for instability or

sluggish control points throughout this range. As a way of

allowing turbine control optimization, the CPC includes an

eleven-point linearization table to allow turbine OEMs or

users to compensate for poor valve linearization by digitally

linearizing the control to valve flow relationship.

Because many turbine users utilize redundant pressure

converters to increase system reliability, and because these

type of applications are prone to silting build-up problems in

the slave unit, a special “Silt Buster” (patent pending) routine

is also configurable to routinely remove internal silt build-up.

Accessories

A standard steel adapter plate is available to allow the CPC

to easily interface with systems designed for Voith I/H

converters.

Specifications

Performance

Accuracy: < ±0.2 % of full range

Repeatability: 0.1 % of full range

Temperature Drift: < ±0.01 % of full range /°C

Pressure stability: < ±2 % of setpoint

Failsafe Operation: Internal return spring forces Control Port

oil to drain port on loss of power or detected failures

Configuration: Computer based Service Tool (RS-232

communications port)

Physical

Dimensions: See outline drawings

Height x Width x Depth: Approx. (290 x 270 x 270) mm

Weight: Approximately 25 kg (55 lb) without oil

Fluid Ports: See outline drawings

Mounting: Any attitude, Four M10 threaded holes,

23 mm deep, on the face with the hydraulic ports.

Adequate support must be provided for the unit.

Environmental

Operating Temperature Range: (–40 to +85) °C

Hydraulic Supply Temperature: (15 to 70) °C

Immunity: EN61000-6-2 (2005)

Emissions: EN61000-6-4 (2007)

Shock: US MIL-STD-810C method 516.2. procedure 1 (10 G

Peak, 11 ms duration, saw tooth waveform)

Vibration: US MIL-STD 810F, M514.5A, Cat. 4 (0.015 G²/Hz,

(10 to 500) Hz, 1.04 Grms)

Ingress Protection: IP66 per EN 60529

Electrical

CPC-II

Input Supply: (18 to 32) V (dc) @ 1.5 A steady state, 8 A

peak (100 ms)

Analog Input Signals: Isolated (4 to 20) mA (250 Ω input

impedance)

Analog Output Signal: (4 to 20) mA; maximum external load:

300 Ω, Accuracy = ±1 % of full scale

Discrete Inputs: Optically Isolated (requires 24 V (dc) wetting

voltage)

Discrete Output Rating: 1 A @ 30 V (dc)

Service Tool Port: RS-232 communications via straight

through serial cable

Hydraulic

Fluid Types: Mineral or synthetic based oils may be used.

Contact Woodward for specific oil recommendations.

Maximum Input Supply Pressure: 25 bar / 363 psi

CPC-II Model

Maximum Output

Pressure Range*

Location

Rating

9907-1197

(0 to 25) bar /

(0 to 363) psi

Zone 1 & 2

9907-1198

(0 to 25) bar /

(0 to 363) psi

Zone 2

9907-1199

(0 to 10) bar /

(0 to 145) psi

Zone 1 & 2

9907-1200

(0 to 10) bar /

(0 to 145) psi

Zone 2

9907-1228

(0 to 10) bar /

(0 to 145) psi

Zone 2

9907-1349

Zone 1 & 2

(0 to 10) bar /

(0 to 145) psi

* Note: The recommended maximum output pressure is less than

70 % of the supply for the best dynamic performance.

Recommended Filtration: (24 to 40) μm nominal, β75 or ISO

20/16 Class

Recommended Viscosity 20 to 100 cSt

Specific Gravity: 0.6 to 1.0

Flow Capacity: Depends on viscosity and pressure difference

(see Figure 3)

Return/Drain Pressure: Maximum 2 bar (29 psi)

Regulatory Compliance

(Listings are limited only to those units bearing the

appropriate Marking or Agency Identification)

European Compliance for CE Marking:

EMC Directive: 2014/30/EU

ATEX Directive: 2014/34/EU For Zone 1: SIRA

11ATEX1310X II 2 G, Ex db IIB T4 Gb. For Zone 2: II 3 G Ex

nA IIC T4 Gc

Other European Compliance: (Compliance with the

following European Directives or standards does not qualify

this product for application of the CE Marking)

Machinery Directive: Compliant as a partly completed

machinery per 2006/42/EC

Pressure Equipment Directive: Compliant as “SEP” per

Article 4.3 to 2014/68/EU

Other International Compliance:

EAC Customs Union: Certified to Technical Regulation CU

012/2011 for use in potentially explosive atmospheres as Ex

d IIB T4 Gb X or 2Ex nA IIC T4 Gc X.

EAC Customs Union: Declared to Technical Regulation CU

020/2011 On Electromagnetic Compatibility of Technical

Equipment.

IECEx: Certified for use in explosive atmospheres per IECEx

Certificate IECEx CSA 11.0017X Zone 1: Ex d IIB T4 Gb and

Zone 2: Ex nA IIC T4 Gc

North American Compliance:

CSA: CSA Certified for Class I, Div. 1. Groups C and D and

Class I, Div. 2. Groups A, B, C, and D, T4 at 85°C Ambient.

For use in Canada and the United States

8290-189-EPG-installation-manual 8290-044

Installation and Operation Manual

This manual covers Electrically Power Governor (EPG) models 512/524 and

1712/1724. Refer to the appropriate manual or contact Woodward for information

about other versions of the EPG.

Application

The EPG is used to control the speed of diesel, gas, and gasoline engines. It can

also control the speed of gas turbines. Installation of EPG actuators is simple

because they require neither mechanical drive nor hydraulic supply.

The EPG handles prime movers with mechanical loads and generator loads

equally well. Generator sets which will be paralleled, however, require additional

appropriate switch gear, current and potential transformers, and the Woodward

Generator Load Sensor.

An EPG is a three-component system, requiring a magnetic pickup, speed

control, and actuator.

A battery charger must be used to keep the battery charged. Maximum steady

state current consumption is 4 A for the 12-volt models (512/1712), and 3 A for

the 24-volt models (524/1724).

Part Number Selection

Use EPG Model 512/1712 for operation in 12-volt systems. Use Model 524/1724

for operation in 24-volt systems.

Additionally, speed controls are available for four ranges of magnetic pickup

frequencies, for diesel engines and gas turbines, or for gasoline and gas

engines. Actuators have a double-ended output shaft for either clockwise or

counterclockwise rotation to increase fuel.

Speed controls and actuators must be compatible. Use the Part Number

Selection Table below (Table 1-1) to choose compatible EPG speed controls and

actuators.

8290-189-EPG

The optional Start Fuel Limit feature allows setting a maximum actuator position

during start-up. The maximum position remains in effect until the engine reaches

the selected idle or rated speed. The limit may be adjusted out of the way by

turning the adjustment potentiometer fully clockwise.

The Dual Dynamics feature allows tailoring a special set of responses for

unloaded and loaded operating conditions. This type of control is often needed

for gas engines and other systems with non-linear fuel systems. A switch is used

to change between slow and fast dynamics.

Accessories

This manual includes some information about accessories frequently used with

EPGs.

To Parallel Generators

Add the Generator Load Sensor to the EPG in paralleled generator applications.

Woodward makes many accessories for paralleled generator applications.

To Decrease Acceleration and Deceleration

The Ramp Generator or an optional, external capacitor can be used to increase

the time to go from idle to rated speeds and vice versa. The Ramp Generator

provides a linear ramp with times adjustable to 25 seconds in a typical case. It is

useful in smoke-limiting applications. Use the 8271-909 with 24 V batteries and

the 8271-910 for 12 V batteries. The capacitor provides an exponential ramp with

times up to four seconds. Exponential means it changes (speed in this case)

rapidly at first but slows as it approaches its final value. See the typical wiring

diagram for capacitor requirements.

References

These publications can be obtained from your Woodward authorized Distributor

or AISF (Authorized Independent Service Facility). All are also available on the

Woodward website (www.woodward.com).

Catalog

52122

Product

Specification

04106

Manual

25070

82510

Title

Woodward Industrial Control Product Line Catalog

Title

Model 512/1712 & 524/1724 Electrically Powered Governors

Title

Electric Governor Installation Guide

Magnetic Pickups for Electric Governors

direction of rotation for increased fuel by choosing a suitable linkage.

If you are using a Woodward supplied installation kit, follow its instructions and

skip over Linkage Compatibility. Begin again with Installing the Magnetic Pickup.

Linkage Compatibility

Also match linkage linearity to the fuel control. Use a linear linkage as shown in

Figure 2-2 unless the prime mover has a carburetor or other non-linear fuel

control. See Figures 2-3 and 2-4 for a carburetor compensating linkage. Contact

Woodward if a linkage different from those shown is required. Incorrect linearity

matching can cause stable operation at some fuel settings but oscillation at other

fuel settings.

A return spring is included in the actuator. Do not use an additional return spring.

(Low force return springs that may be located in an engine’s valve cover usually

don’t affect EPG performance.)

Make sure that the actuator is capable of moving the fuel control to the maximum

and minimum limits. Let the fuel control limit actuator travel. Set the linkage so

that the actuator is just above minimum when the fuel control is at its minimum

stop and (except for Detroit Diesel engines) so that the actuator is just below

maximum when the fuel control is at its maximum stop. We recommend that

Woodward installation kits be used for Detroit Diesel engines.

Use good rod end connectors. The link connecting the actuator lever to the fuel

control lever must not be so long that it flexes when the prime mover is running.

Installing the Magnetic Pickup

Mount the magnetic pickup through a housing or rigid bracket. Make sure that

the sensed gear is of magnetic material. The gap between the pickup and the

outside diameter of the gear should be set to approximately 1.0 mm (0.04”) at the

closest point (radial runout). Using the pickup with small gears may require

spacing as close as 0.25 mm (0.010”).

If you cannot measure the gap directly, it can be set in this manner: with the

prime mover shut down, turn the pickup in (clockwise) until it touches the outside

diameter of a tooth. Then back out the pickup (counterclockwise) approximately

three-quarters of a turn. Run the gear slowly through 360 degree rotation to

check the clearance of the pickup. When the gap is set, tighten the jam nut

securely against the housing or bracket.

The standard pickup models require mating connectors, MS 3102R-18-3P. The

connectors are not furnished with the pickup, but may be ordered from

Woodward if desired. See manual 82510. Magnetic Pickups and Proximity

Switches for Electronic Controls, for more information

Wiring Instructions

Use a wiring diagram for the specific part number of your EPG system to make

all wiring connections. The wiring diagram is available from Woodward. Typical

wiring is shown in Figure 2-5.

Make all connections using insulated terminals. The wiring from actuator to

speed control and from the battery to the speed control must be as short as

possible. Maximum wiring lengths are:

Maximum Wiring Length Chart

8290-189-EPG

EPG Model

14 AWG

(2 mm²)

Maximum Wire Length

12 AWG

(3 mm²)

512/1712

10 ft (3 m)

524/1724

20 ft (6 m)

35 ft (11 m)

75 ft (23 m)

The fuse and switch or circuit breaker must be in the non-grounded battery lead.

Use a fuse or circuit breaker as specified in the Switch and Fuse Requirements

Chart. Do not use a fuse of higher current rating. Starter relays make good EPG

power switches.

Installation Checks

Checks for all Applications

The following steps check only the speed control and actuator, which must work

correctly before paralleling the generator. Since most faults appear when the

prime mover is first run, this step-by-step approach eliminates most problems

before they occur. The main part of Chapter 5 (Troubleshooting) is doing these

checks.

If a Load Sensor is used, temporarily remove the wires at speed control terminals

11 and 12 and temporarily jumper terminals 11 to 12. The generator must not be

paralleled during these tests. If a Ramp Generator is used, temporarily remove

the wire at speed control terminal 10. If a capacitor is connected to terminal 10 to

provide a ramp between unloaded and loaded, it must be removed during this

test or calibration. Leave the idle-rated switch wiring connected. Do the checks in

the order indicated. Terminal numbers in this section refer to the speed control.

Check that all electrical connections are correctly made and terminal screws

are tight; the magnetic pickup is properly installed and the jam nut is tight;

the actuator and linkage are securely fastened. If start-fuel limit is present,

turn the adjustment fully clockwise during these tests. If dual dynamics are

present, set the switch closed for slow dynamics.

2. Do not start the prime mover now. Turn on governor power. If the fuse or

breaker opens as soon as power is applied, the battery polarity (terminals

14 and 15) is probably reversed. The actuator shaft can jump when power is

turned on, but must quickly come back to the minimum fuel position. Check

the battery voltage at terminal 1 (+) and 2 (–). It must be from 10 to 16 Vdc

for 512/1712 controls, and from 20 to 32 Vdc for 524/1724 controls.

Disconnect any wiring or jumper on terminal 7. Measure 7.2 ±1.0 V from

terminal 2 (–) to 7 (+) [terminals 2 (–) to 9 (+) for dual-dynamics control].

Reinstall the wiring to terminal 7 if voltage is correct. Do not use the control

if voltage is incorrect.

If idle speed is desired, connect a 50 kΩ potentiometer or fixed resistor to

terminals 9 and 10 as shown in the typical wiring diagram. To calculate the

value of a fixed resistor:

R = 17 kΩ

( Rated Speed

Idle Speed – 1 )

Put the idle-rated switch in the rated position or jumper terminals 9 and 10.

Measure the voltage from terminal 7 (+) to 2 (–). Put the idle-rated switch in

the idle position or remove the jumper. The voltage must increase. If it does

not increase, check the speed trim pot, if used, and the idle-rated switch

wiring.

If a signal generator with an isolated output is available, the failsafe and

actuator travel can be checked, Rated and idle speed can be preset. If a

signal generator is not available, skip to step 7.

Turn off governor power. Remove the magnetic pickup wires from terminals

5 and 6. Connect the signal generator to terminals 5 and 6. Set the output

between 2 and 10 Vrms. The wave form can be sine, square, or triangular.

Calculate the MPU frequency for idle and rated speeds (see part number

selection in Chapter 1).

Check Failsafe and Actuator Travel:

Set the signal-generator frequency to about half of idle speed. Set the idle

rated switch to rated. Turn the signal generator and governor power on. The

linkage must be at the maximum-fuel position. Except for Detroit Diesel

engines, verify that linkage travel is limited by the prime-mover fuel control,

not by the actuator stop. Turn the signal generator off and remove the

connections at terminals 5 and 6. The linkage should move to the minimum

fuel position. Verify that linkage travel is limited by the prime mover’s fuel

control, not by the actuator stop.

Preset Rated Speed:

Set the signal generator for MPU frequency at rated speed and connect it to

terminals 5 and 6. Put the idle-rated switch in the rated position. Set the

speed trim pot, if connected, to mid-position. Observe the linkage position.

If the linkage Is at the maximum fuel position:

Slowly turn the rated speed pot counterclockwise until the linkage just

begins to move to the minimum fuel position. Start Fuel (if present) must be

adjusted to the maximum clockwise position or the actuator will not move to

maximum.

If the linkage Is at the minimum fuel position:

Slowly turn the rated speed pot clockwise until the linkage just begins to

move to the maximum fuel position.

Continue to adjust the rated speed pot very slowly in the appropriate

direction, trying to stop the linkage between the minimum and maximum fuel

stops. Because it is not possible to stop the motion, cease adjusting when

the linkage moves slowly. The rated speed reference is now set very close

to desired speed. A slight adjustment when the engine is running will

achieve the exact speed.

Preset Idle Speed:

Preset idle speed only after presetting rated speed. Set the signal generator

for the MPU frequency at idle speed. Put the idle-rated switch in the idle

pos

Product Change Notification 06946A

Overview

In January, 2018. Woodward released new ProTech-GII models and a Field Software Conversion

kit. The new models include the same functionality as the older ProTech-GII models but with

many product improvements and enhancements. Woodward recommends that customers who

are purchasing ProTech-GII units for use in new applications order part numbers from the “new”

part number list only. Refer to product manual 35086 for detailed product information.

Customers with older ProTech GII models (Rev D or later) may use the new Field Software

Conversion kit to upgrade/convert their units to the new ProTech-GII models. Manual 51582

describes the conversion process.

Description of Changes

The new ProTech-GII software program is based on the older ProTech-GII software program and

includes the below listed improvements/enhancements.

• Speed Loss (sudden speed loss): The failure threshold was made configurable and the fault

action was expanded to include a selection of ‘not used’.

• Increased allowable ranges for speed settings from 32000 to 80000 rpm to facilitate turbo

expander applications. The maximum speed frequency remains at 32 kHz.

• A configurable low-pass filter was added to the acceleration signal.

• Chinese language support added as a configuration setting.

• Front Panel Display changes:

• Speed display: Configurable filter added to the displayed speed value to reduce displayed speed

variations. The precision of the speed value on the front panel provides one decimal precision

when below 100 rpm.

• Improved front panel performance, providing faster response to a key press.

o Trip button (front panel): Toggles display between the Trip Log and the Trip Latch.

o Alarm button (front panel): Toggles display between the Alarm Log and the Alarm Latch.

o Added Shared Reset, Shared Start and Shared Speed Fail Override display screens

o Rearranged Trip Latch inputs to display more practical faults first (e.g. overspeed).

o Auto Sequence Test: Displayed test result is for the entire sequence, not just the local

module

• Modbus changes:

o The outputs of all analog logic blocks have been included as Modbus analog/register reads.

o Changed the address numbering (Boolean and register) to be consecutive, removing huge

gaps in numbering.

o Added Spare Boolean read registers to prevent errors experienced by devices that queried in

increments of 16.

o Added Scaled analog reads for speed and acceleration to accommodate values exceeding

the 16-bit limits.

Compatibility Notes and Table

• Field Software Conversion kit 8929-039 can be used to convert any ProTech GII that is Rev D or

later to the new models listed below. See table below for compatibility information.

Description Part Numbers that Can Be Converted

ProTech-GII – Bulkhead Mount, HV/LV, Ind. Relays  8237‐1244 Rev D or Newer or 8237-1594

ProTech-GII – Bulkhead Mount, HV/HV, Ind. Relays  8237‐1245 Rev D or Newer or 8237-1595

ProTech-GII – Bulkhead Mount, HV/LV, Voted Relays  8237‐1246 Rev D or Newer or 8237-1596

ProTech-GII – Bulkhead Mount, HV/HV, Voted Relays  8237‐1247 Rev D or Newer or 8237-1597

ProTech-GII – Panel Mount, HV/LV, Ind. Relays  8237‐1367 Rev D or Newer or 8237-1598

ProTech-GII – Panel Mount, HV/HV, Ind. Relays  8237‐1368 Rev D or Newer or 8237-1599

ProTech-GII – Panel Mount, HV/LV, Voted Relays  8237‐1369 Rev D or Newer or 8237-1600

ProTech-GII – Panel Mount, HV/HV, Voted Relays  8237‐1370 Rev D or Newer or 8237-1601

ProTech-GII – Field Software Conversion Kit 8929-039

• Although optional when configuring the ProTech-GII, Woodward’s ProTech Service Tool

(9927-1810 Rev. J) is compatible with all new and old ProTech-GII models and can be obtained/

downloaded from Woodward’s website.

• Configuration files from older ProTech-GII models can be loaded into new ProTech-GII models

using the ProTech-GII service tool. However, configuration files from new ProTech-GII models

cannot be loaded into older ProTech-GII models.

• Customer with units older than Rev. D can return their units to Woodward for upgrade.

New Model Numbers

The following table shows the new/improved ProTech-GII part numbers:

Description Non-Preferred

Part Number

New Part

Number

ProTech-GII – Bulkhead Mount, HV/LV, Ind. Relays  8237-1594 8237-2594

ProTech-GII – Bulkhead Mount, HV/HV, Ind. Relays  8237-1595 8237-2595

ProTech-GII – Bulkhead Mount, HV/LV, Voted Relays  8237-1596 8237-2596

ProTech-GII – Bulkhead Mount, HV/HV, Voted Relays  8237-1597 8237-2597

ProTech-GII – Panel Mount, HV/LV, Ind. Relays  8237-1598 8237-2598

ProTech-GII – Panel Mount, HV/HV, Ind. Relays  8237-1599 8237-2599

ProTech-GII – Panel Mount, HV/LV, Voted Relays  8237-1600 8237-2600

ProTech-GII – Panel Mount, HV/HV, Voted Relays  8237-1601 8237-2601

ProTech-GII – Field Software Conversion Kit  8929-039

Customer Action

• Customers who are currently using any ProTech-GII model and do not require any of the above

listed changes/improvements should take no action. Woodward will continue to support the listed

“non-preferred” models. Refer to the related product support plan for these models.

• Woodward recommends that customers who are purchasing ProTech-GII units for use in new

applications order part numbers from the new part number list only.

• Customers who currently own an older ProTech-GII model and wish to have/utilize one or more

of the above listed changes/improvements can send their old ProTech-GII model into Woodward

Colorado, USA for a conversion to a new model. Optionally, if their current model is Rev. D or

later, they can purchase Field Software Conversion Kit 8929-039 and install the conversion

themselves or schedule a field conversion by an authorized Woodward field service engineer.

Product Change Notification 06912

(Revision B, 6/2013)

Overview

Woodward is releasing new ProTech®-GII models on 17 May 2013. These new models include the same

basic functionality as current ProTech-GII models, and include the improvements listed below as well as

new capabilities.

In an effort to minimize the risk of future application issues, and since the new/improved models are direct

drop-in replacements for the existing models, Woodward plans to change all existing models to “non

preferred” on 15 July 2013. and all new models to “preferred”. Refer to Table 1 below for specific part

number information. Depending on the migration rate to the new ProTech-GII models, Woodward plans to

inactivate all old non-preferred models within the next 12 to 18 months. Please inform affected purchasing

teams and customers accordingly.

Product Change / Improvement

The below listed “preferred” models include the following changes, improvements, and additions:

1.

All module speed inputs are shared with all other modules (A, B, C).

All module trip and alarm latch output statuses are shared with all other modules (A, B, C).

All module “Start”, “Reset”, and “Speed Failed Override” commands are shared with all other modules

(A, B, C).

Added Speed Redundancy Manager Block:

With all input sensors/channels healthy, each module to be configured to select the desired

speed (median, HSS, or LSS) to use for its alarm and trip logic.

Upon one failed input sensor/channel, each module to be configured to select the desired speed

(HSS or LSS) to use for its alarm and trip logic.

Upon two failed input sensors/channels, each module to be configured to select the desired

action (issue a trip command or use healthy speed input sensor/channel for its alarm and trip

logic).

Allows users to configure the use of 3 or 2 or 1 speed input sensors/channels.

Includes “Speed Difference Detection” alarm function. Note that this feature can be easily used to

assist in detecting a failed active or passive speed sensor.

Note: New speed redundancy manager logic allows users to configure the voting logic to meet Shell’s

2-out-of-2 voting requirement when only two inputs are available/healthy.

Added Acceleration Redundancy Manager Block:

With all input sensors/channels healthy, each module to be configured to select the desired

acceleration rate (median, HSS, or LSS) to use for its alarm and trip logic.

Upon one failed input sensor/channel, each module to be configured to select the desired

acceleration rate (HSS or LSS) to use for its alarm and trip logic.

Allows users to configure the use of 3 or 2 or 1 speed input sensors/channels.

Added Boolean Input Manager Functions:

Each of the ProTech-GII’s contact/Boolean inputs (Start, Reset, and Speed Failed Override) can

be configured to use the respective contact/Boolean input command from any or all of the other

modules.

When configured, any or all of the configured discrete input commands are “ORed” together.

Example—If module A’s “Reset” function is configured to use module A’s and module B’s “Reset”

contact input commands, then a “Reset” command received from the A or B module will activate

module A’s Reset logic.

Boolean Input Manager functions can only be configured from the ProTech-GII’s PCT software

service tool.

The ORed Boolean Input Manager functions, if configured, only manage the action of a module’s

contact inputs commands. The Reset and Start keys on the module’s front panel function

independently of the Boolean Input Manager and only affect the respective module’s action.

Added configurable “Failed Power Supply #1” and “Failed Power Supply #2” Alarm Override functions.

Allows users to configure the module to accept only one power supply, thus removing a nuisance

Failed Power Supply Alarm indication.

Changed Speed Fail Alarm function to be overridden during the turbine start state/mode.

This removes a nuisance alarm during a turbine start-up.

Changed Speed Lost Alarm/Trip threshold level from 100 Hz to 200 Hz to reduce/remove nuisance

alarms/trips when applied with speed gears that have less than 60 teeth and turbines that can slow roll

at low speeds.

10. Changed the name of “Periodic Overspeed Test” to “Auto Sequence Test”.

11. Added an option to start the Auto Sequence Test Routine from the Auto Sequence Test screen. This

allows a user to instantly start the Auto Sequence Test function when desired.

12. Added an option to disable Auto Sequence Test routine from the Auto Sequence Test screen. This

allows a user to disable the Auto Sequence Test function from being performed. Since the Auto

Sequence Test routine can be configured to be performed on a periodic basis, the “Disable” function

allows users to temporarily disable the periodic test routine from being performed when desired.

13. Added an Auto Simulated Speed Test Failed Alarm to indicate the failure of the Auto Simulated Test

routine.

14. Added a configurable permissive for any Test routine, which will not allow the Test function to be

started if any other module has an “Alarm” condition active. Users now have the following configurable

Test “permissive” options: None, Module Not Tripped, or Module Not In Alarm. If configured, the test

routine’s permissive logic does not allow a module’s Test function to operate if any module is in its

Tripped or Alarmed State (user configurable).

15. Added the ability to configure/select the screen to be shown as the Home Screen.

16. Added a configurable option to not jump to Home Screen on a trip condition.

17. Added an Overspeed Setpoint analog read value/register to Modbus® * communications.

* Modbus is a trademark of Schneider Automation Inc.

18. Added the ability to configure the module’s Trip Latch function to be latching or non-latching.

19. Added the option to configure a module’s Speed Probe Type to “Passive”, “Active”, and “Not Used”.

The “Not Used” option allows users to wire two speed probes into only two of the ProTech-GII

modules, and not have related nuisance alarms.

20. Added Date & Time Stamp information to the Peak Speed/Acceleration Log.

21. Added a configurable option to include the module’s trip state into the module’s Alarm Latch logic. This

capability allows any module trip to be indicated as a module Alarm condition also and functions the

same as the original ProTech 203 logic.

22. Added an option for users to issue a module trip command when entering the module’s “Configuration”

mode. Note: Entry of the “Configuration Level” password is required for users to issue module trip

command from the module’s front panel.

23. Added a configuration change time stamp function which records and displays the date and time of the

last configuration change was saved to memory (via the front panel or service tool).

The following table shows the new “preferred” ProTech-GII part numbers:

Description

Number

ProTech-GII – Bulkhead Mount, HV/LV, ind. relay 8237-1244 8237-1594

ProTech-GII – Bulkhead Mount, HV/HV, ind. relay 8237-1245 8237-1595

ProTech-GII – Bulkhead Mount, HV/LV, voted relays 8237-1246 8237-1596

ProTech-GII – Bulkhead Mount, HV/HV, voted relays 8237-1247 8237-1597

ProTech-GII – Bulkhead Mount, HV/HV, voted relays – limited front panel config. 8237-1656 8237-1597

ProTech-GII – Panel Mount, HV/LV, ind. relay 8237-1367 8237-1598

ProTech-GII – Panel Mount, HV/HV, ind. relay 8237-1368 8237-1599

ProTech-GII – Panel Mount, HV/LV, voted relays 8237-1369 8237-1600

ProTech-GII – Panel Mount, HV/HV, voted relays 8237-1370 8237-1601

ProTech-GII – Panel Mount, HV/HV, voted relays – limited front panel config. 8237-1660 8237-1601

Spare Module for ProTech models 8237-1596 & 8237-1600 5437-1119 5437-1124

Spare Module for ProTech models 8237-1597 & 8237-1601 5437-1120 5437-1125

Spare Module for ProTech models 8237-1594 & 8237-1598 5437-1121 5437-1126

Spare Module for ProTech models 8237-1595 & 8237-1599 5437-1122 5437-1127

8273-140

The Woodward 2301D 8273-140 Load Sharing and Speed Control Module

273-140 Technical Specifications

Manufacturer    Woodward

Unique Product Series    2301D Digital Load Sharing/Speed Controls

Functional Description    8273-140 Load Sharing and Speed Control Module

Functional Part Number    8273-140

About the 8273-140

This 8273-140 Load Sharing and Speed Control Module was fittingly originally developed for the 2301D Series of Load Sharing and Speed Control-oriented products.

This particular product series adopts the D letter as a reference to its digital status.

This particular 8273-140 Load Sharing and Speed Control Module part is actually the “before” product of the 8273-501 Load Sharing/Speed Control Module of the exact functional title.

As far as we can tell, no major revisions have been installed in the assembly of this 8273-140 product offering.

8273-140 Load Sharing/Speed Control Hardware Chosen

This 8273-140 Load Sharing and Speed Control Module product’s official Woodward-recognized functionality as such is introduced through the adoption of several specialized hardware components.

8273-140

To kick us off, one immediately-noticeable was specifically designated to exist in an ordinary mounting location, as the cousin 8273-141 Load Sharing product is actually the one that Woodward designates for HazLoc or Hazardous Locations.

Some of the other critical hardware features included with this 8273-140 Load Sharing and Speed Control Module are its:

Metallic installation backplane with both holes and slots

Front-facing long terminal strip or port

Measurement guide printed on the surface

Metallic protective chassis designating modular style

The Woodward BUM60 (manufactured under the Baumüller partnership) and the 3522-1004 represent a sophisticated motor drive and control assembly.

1 Specifically, the BUM60 is a high-performance modular servo drive often integrated into Woodward’s turbine or engine control systems to provide precise electronic actuation for fuel valves or steam racks.2

Introduction

The BUM60-1224… is a “back-of-panel” modular servo inverter, while the 3522-1004 is often the associated control module or firmware-specific hardware designation.

Together, they form a closed-loop system capable of controlling synchronous or asynchronous motors with high dynamic response.

This specific configuration (indicated by the long alphanumeric string) defines the power stage, control type (VC – Vector Control), and specialized cooling or communication options.

Technical Parameter Table

Parameter	Specification
Model Number	BUM60-1224-54-B-001-VC-A0… / 3522-1004
Input Voltage	400–480 VAC, 3-Phase
Current Rating	12A (Nominal) / 24A (Peak)
Control Method	VC (Vector Control) for high precision
Power Output	Approximately 8–10 kW (Application dependent)
Communication	CANopen / RS-485 (VC interface)
Protection Class	IP20 (Cabinet Installation)
Cooling	Forced Air (Internal fan)
Feedback Types	Resolver / Encoder / SinCos

Related Models

In a Woodward/Baumüller ecosystem, this unit often interfaces with:

F-Series Actuators: High-speed electric actuators for gas/steam valves.

BUS60 Series: Power supply modules for DC bus linking.

BUM62 Series: Larger power variants for higher torque applications.

Woodward 505/MicroNet: The primary turbine controllers that send commands to this drive.

BUM60

Application Cases

Electric Actuation for Large Valves: Replacing pneumatic or hydraulic systems on gas turbines for faster, more precise fuel metering.3

Steam Turbine Needle Control: Managing the position of steam admission valves in power plants.

Variable Speed Pump Drives: Controlling cooling or lubricating oil pumps in heavy industrial skids.

Compressor Guide Vanes: Precise positioning of inlet guide vanes (IGV) to optimize compressor efficiency.

BUM60

Product Advantages and Features

Extreme Precision (VC Mode): The Vector Control (VC) capability allows for maximum torque even at zero speed, which is critical for holding valve positions against high pressure.

Modular Design: The “BUM” series allows for the separation of the power stage and the control unit, making maintenance and troubleshooting simpler.

High Dynamic Response: Capable of millisecond-level response times, ensuring the turbine can react instantly to load changes or emergency trips.4

Integrated Safety: Features built-in monitoring for overcurrent, overvoltage, and thermal protection to prevent damage to the motor or the drive itself.5

Specialized Woodward Firmware: The long part number identifies specific Woodward-tailored parameters that optimize the drive for turbine-specific actuators.

Other Models in the Same Series

The BUM60 series is highly customizable based on the suffix code:

BUM60-0306: Smallest power variant (3A/6A).

BUM60-3060: Larger power variant (30A/60A).

BUM60-VC: Vector Control specific variant (like yours).

BUM60-SR: Resolver-based feedback variant.

5466-258

Woodward 5466-258 Simplex 48/24 Discrete Input/Output Module for Both MicroNet and Vertex-Pro Chassis.

This unit has 1 Red Fault LED and is UL/ATEX Listed. The 5466-258 unit is part of the Vertex-Pro system for MicroNet Digital Controllers.

5466-258 Technical Specifications

Air Quality    Pollution Degree 2

Control Type    Vertex-Pro Motor-Driven Compressor

Installation Overvoltage Rating    Category II

Listings    IL, ATEX, CE(EMC), DNV, ABS, and LRS

Module Type    Simplex Discrete 48/24 I/O Module

Operating Temperature Range    0-55°C

Storage Temperature    -40 to +105 °F

Weight    48 lbs. (22 kg) when in Chassis

About the 5466-258

The 5466-258 module is a Simplex Discrete Input/Output unit. The unit was produced by Woodward as part of the MicroNet Digital Control series which can also be used with a Vertex-Pro Chassis.

The typical hardware used with this unit is the MicroNet Plus hardware.

This module can be used in both Simplex and Redundant systems.

This module can be used in any chassis module, whether eight or fourteen slots.

Please note the locations for this unit must be non-hazardous or within Class I, Division 2. Groups A, B, C, and D.

The 5466-258 module is a forty-eight/twenty-four discrete combo module, this indicates that there are forty-eight inputs and twenty-four outputs.

There are two configurations that the module can be used in. One of them will consist of two twenty-four/twelve discrete FTMs which will connect to this module through two high-density discrete/analog cables.

The discrete inputs on this module will be optically isolated and can be accessed through the twenty-four/twelve FTMs when in the second configuration.

On the front faceplate, there is only one LED which indicates the potential faults. There are also two connectors on the module.

Woodward 9907-1200 Current-to-Pressure Converter (CPC-II)

The Woodward 9907-1200. also known as the CPC-II Current-to-Pressure Converter, serves as a sophisticated electrohydraulic valve control unit used within turbine and engine management systems.

It is designed to convert an electrical input current into a hydraulic pressure output, which actuates steam turbine valves with high precision.

Positioned as a key component in turbine speed and load control loops, the module enables enhanced dynamics and robust performance in complex control architectures.

9907-1200

For system adaptability, the 9907-1200 includes a manual override function allowing local adjustment of output pressure, alongside remote configuration and calibration via a service tool.

It features an eleven-point linearization table to compensate for non-linear valve flow characteristics and a silt buster function to periodically flush potential contaminant buildup, both optimizing turbine control and longevity.

Its robust operating temperature range (-40°C to +85°C) and IP66 ingress protection ensure functionality in challenging environmental conditions, while the compact form factor and flexible mounting options facilitate straightforward integration into control panels.

Detailed Technical Specifications

Parameter    Value

Model    9907-1200

Brand    Woodward

Product Type    Current-to-Pressure Converter (CPC-II)

Pressure Range    0 to 10 bar (0 to 145 psi)

Input Signal    4 to 20 mA (configurable)

Output Signal    Electrohydraulic pressure control

Operating Temperature    -40 to +85 °C

Power Supply    18 to 32 V DC, nominal 24 V DC

Max Current Output    8 Amps

Mounting    Face mounting with threaded holes

Protection Rating    IP66

Redundancy Support    Yes (dual input/controller capable)

Dimensions (approx.)    290 x 270 x 270 mm

Weight    Approximately 25 kg

Related Modules or Compatible Units

9907-1100 – Similar current-to-pressure converter supporting different pressure ranges for varied turbine applications.

9907-055 – Electrohydraulic actuator controller designed for integration with Woodward control systems.

9907-072 – Enhanced valve servo control module with additional redundancy features.

9907-076 – Complementary control module providing advanced diagnostics and feedback capabilities.

9907-077 – Compact electrohydraulic valve control module for smaller scale engine applications.

9907-105 – Current-to-pressure converter variant optimized for higher pressure applications.

8200-1302

Woodward Series 505D Digital Governor Turbine Control Product 8200-1302 is an integrated graphical front panel HMI that features Marine/ATEX Compliance LVDC (18-32 Vdc).

8200-1302 Technical Specifications

Analog Input    4-20 mA channels (with Loop Power)

EMC Immunity    EN 61000-6-2

Enclosure Type    IACS UR E10 (Commercial Marine)

Features    ATEX, IP-54. and Pollution Degree 3

Input Voltage    LV 18-36 VDC isolated

Operating Temperature    -22 – 158 F

Screen Size    8.4in LCD

Storage Temperature    -22 – 158 F

About the 8200-1302

The 8200-1302 is one of several Woodward 505 Digital Governors available for the control of steam turbines.

This operator control panel acts as a graphical interface and keypad that allows for adjustments to and communication with the turbine. This can be configured through Modbus communication ports located on the unit.

The 8200-1302 has multiple features available:

Auto start sequencing for hot and cold starts, with temperature input options

Critical speed avoidance on three-speed bands

Ten external alarm inputs

Ten external DI trip inputs

Trip indication for Trip and Alarm events with associated RTC time stamp

Dual Speed and Load Dynamics

Peak Speed Indication for Overspeed Trip

Zero Speed Detection

Remote droop

Frequency dead-band

The unit also offers three normal operating modes, including configuration, operation, and calibration modes.

The unit includes two redundant speed inputs that can accept magnetic pickup units, eddy current probes, or proximity probes.

It has analog inputs (8) that can be configured for any of twenty-seven functions.

The unit also has an additional twenty contact inputs.

The first four of these contacts default for shutdown raise speed setpoint, reset, and lower speed set point.

The others can be configured as needed. Additionally, the unit has two 4-20 mA control outputs and eight Form-C relay contact outputs.

The 8200-1302’s front panel includes an emergency trip key, a backspace/delete key, a shift key, as well as view, mode, ESC, and home keys.

It also has navigation cross keys, soft key commands, and four LEDs to relate the status of control and hardware.

the Woodward 8901-457 is a high-precision Current-to-Pressure (I/P) Transducer, specifically designed for industrial turbine and engine control applications.

It acts as the critical interface between electronic control systems and pneumatic actuators, converting a standard electrical signal into a proportional pneumatic output to position valves or fuel racks.

Technical Parameter Table

Parameter	Specification
Model Number	8901-457
Input Signal	4–20 mA (Standard)
Output Pressure Range	3–15 psi (0.2–1.0 bar)
Supply Pressure	20 psi (1.4 bar) recommended; Max 50 psi
Accuracy	< ±0.5% of span
Linearity	< ±1.0% of span
Air Consumption	< 0.11 SCFM at 20 psi supply
Operating Temperature	-40°C to +85°C
Enclosure Rating	NEMA 4X / IP65
Weight	Approximately 1.1 kg (2.4 lbs)

Related Models

The 8901-457 is often utilized alongside these Woodward components:

8200-1300: 505 Series Digital Governor (provides the 4-20mA control signal).1

9907-162: 505 Turbine Controller.2

ProTech-GII: Overspeed protection systems that may trigger the I/P transducer for emergency shutdown.3

CPC II: Current-to-Pressure Converter (a more modern, high-precision electronic alternative).

Application Cases

Steam Turbine Control: Regulating the position of the steam governor valve to maintain constant speed or load.

Gas Turbine Fuel Systems: Controlling the fuel metering valves through pneumatic actuation.

Process Industry Valves: Used in refineries and chemical plants to control large-scale pneumatic control valves where electrical-only actuators are impractical.

Boiler Feedwater Systems: Managing the modulation of feedwater valves based on boiler demand.

8901-457

Product Advantages and Features

Explosion-Proof Design: Certified for use in hazardous areas (Class I, Div 1), making it ideal for oil and gas environments.

Vibration Resistance: Specifically engineered to be mounted directly on or near high-vibration equipment like turbines and engines.

High Flow Capacity: Delivers high pneumatic flow rates, allowing for faster response times in large actuators.

Low Air Consumption: Optimized internal pilot valves minimize the amount of compressed air wasted during steady-state operation.

Field Adjustable: Includes zero and span adjustments that are easily accessible for calibration during commissioning.

8901-457

Other Models in the Same Series

The Woodward 8900/8901 family includes various pressure and signal configurations:

8901-456: Variant with 6–30 psi output range.

8901-458: High-pressure output variant for heavy-duty actuators.

8901-460: Model with internal pressure feedback for enhanced stability.

8910 Series: Low-cost variants for non-hazardous locations.

Introduction

The Woodward 8901-457 is a rugged, field-proven I/P transducer that bridges the gap between digital control logic and mechanical execution.

By translating a 4-20 mA current signal into a highly accurate 3-15 psi pneumatic signal, it allows sophisticated electronic governors to control heavy pneumatic machinery with extreme precision.

Its NEMA 4X housing and vibration-dampened internals ensure a long service life even when exposed to the corrosive and turbulent atmospheres of power plants and refineries.