WELCOME! CONTENTS. Page 04 Woodward Overview 05 Woodward Product Family Overview

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3 WELCOME! This catalog is a concise selection of Woodward standard product lines for advanced combustion controls with specific applications in automotive testing and research and development projects. Woodward manufactures 1000s of products for OEM volume production programs ranging from the simplest combustion controls applications to the most complex in the world. For a complete listing of other Woodward product lines, please visit CONTENTS Page 04 Woodward Overview 05 Woodward Product Family Overview 07 Ignition and Ion Sensing Product Overview 08 SmartFire Instrumentation Ignition 10 SmartFlame Module 12 Actuator and Throttle Body Specification Charts 13 Actuator Product Overview 14 L Series Speed Controller 16 ProAct Digital Plus Actuators 20 ProAct ISC Integrated Speed Control 25 Throttle Body Product Overview 26 L Series ITB Integrated Throttle Body 28 Flo-Tech ITB Integrated Throttle Body/Actuator 32 ProAct ITB Integrated Throttle Body PAGE 3

4 ADVANCED COMBUSTION CONTROLS PRODUCTS OVERVIEW Woodward is the world s largest independent designer, manufacturer, and service provider of energy control solutions for aircraft engines, industrial engines and turbines, power generation, and mobile industrial equipment. The company s innovative control, fuel delivery, and combustion systems help customers worldwide operate cleaner, more reliable, and cost effective equipment. Good control solutions are more than just components and systems. Good solutions also incorporate the experience, expertise, and analytical capabilities that Woodward brings to customers. Backed by knowledge gained from decades of managing and controlling engines of every size, type, and application, Woodward works closely with OEMs and customers at the research and development level to provide well-integrated solutions that help make today s engines and equipment operate more cleanly, reliably and efficiently. Woodward has a full range of products and control system solutions based on four key technologies fuel and air delivery, combustion control, electronic controls and software, and systems integration. With Woodward s fully integrated control system architecture, control system costs can be significantly reduced while performance and network communications capabilities are enhanced. This catalog will focus on the Woodward product lines of actuators, throttle bodies and ignition systems that are relevant to the automotive, industrial and testing markets. PAGE 4

5 WOODWARD PRODUCT FAMILY OVERVIEW PAGE 5

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7 IGNITION AND ION SENSING PRODUCT OVERVIEW SmartFire Instrumentation Ignition The SmartFire ignition controller is the state of the art in combustion electronics. SmartFire and its combustion analysis software, WinFire, can be used to gather combustion data crucial for engine development and tuning with no modifications to the combustion chamber. SmartFire is the first commercially available ignition and engine diagnostic system to fully utilize ionization feedback. SmartFlame Module The SmartFlame module was developed to meet the need of researchers experimenting with ion currents. It provides a simple and convenient method of creating an ion bias voltage. Since the module is totally isolated it is easy to hook up and install. This module is used in conjunction with standard off the shelf NI hardware. It allows for real time acquisition and processing of ion signals. This platform can communicate the data either digitally over a network or analog via any of the many off the shelf modules. The NI systems that hold these modules range in size from 4-module portable systems to large rack mount systems capable of holding hundreds of systems. PAGE 7

8 SmartFire Instrumentation Ignition The SmartFire Instrumentation Ignition system provides the most user-friendly combustion feedback tool available. SmartFire provides individual cylinder feedback in a real time format and is designed to aid dynamometer operators eager to maximize their engine performance. The SmartFire system has applications on gasoline, natural gas, diesel and HCCI engines. On gasoline and natural gas engines the SmartFire system uses high-speed signal processing of the ion signal to detect ALL misfires. When misfires occur SmartFire uses closed loop re-strike to re-ignite the cylinder to prevent combustible mixtures from escaping the combustion chamber. SmartFire detects every occurrence of pre-ignition in the cylinder this feature is not available with conventional acoustic systems. SmartFire makes it possible to calibrate engines using misfire detection and prevention through the tip of the sparkplug without drilling holes. SmartFire is capable of using ion signals to detect knock with greater sensitivity than traditional acoustic transducers. SmartFire enables dynamometer operators to take full advantage of the system s unique ability to do knock calibrations where invasive cylinder pressure sensors are normally required. The system is designed to help maximize engine performance. Through in-cylinder start of combustion flagging on diesel engines, closed loop injection timing control is possible with SmartFire. The system is also able to improve cold startability of diesel engines compared to traditional glow plugs. The SmartFire system is able to provide feedback to control fuel injection and ignition timing on an individual cylinder basis. SmartFire uses ionization feedback to allow the engine builder to dial in the maximum horsepower for each individual cylinder. The SmartFire system includes a PC interface, which allows the operator to view the ionization waveforms of each cylinder in real time. The system can fire and monitor up to 12 cylinders. Knock and misfire displayed on PC software Rapid engine calibration Ion sensing through the tip of the sparkplugs NO DRILLING HOLES Knock detection Misfire Detection for OBD II Misfire Prevention Quicker integration Can be installed and running in as little as 3 hours Runs on Windows 95/98/NT/XP PAGE 8

9 SmartFire Instrumentation Ignition BENEFITS Data Acquisition Ionization can be logged to either the display PC or to the dynamometers high-speed data acquisition system. SmartFire performs knock and misfire detection in a real time format directly through the spark plug, with no extra holes to drill. SmartFire can analyze ionization from any type of fuel. Compatible with any engine the system provides an excellent return on investment. SmartFire s real time display is a useful tool for realtime engine development and diagnostics. Capable of data logging on Dyno and during in car transient testing. SmartFire eliminates drilling of any extra holes in engine to get good combustion information. SmartFire delivers a start of combustion flag for diesel and HCCI engines. SmartFire with its ionization feedback is the ignition technology of the future. Peak Power Optimization individual cylinder readings make tuning much more efficient and effective; resulting in maximum performance from your engine! SmartFire Monitoring Station Dyno Monitoring Station Advanced Combustion Controls 3800 North Wilson Ave. Loveland, CO Ph: +1 (970) Fax: +1 (970) smartfire SPECIFICATIONS Input 12 or 24 Volts. Cylinder Configurations 1 through 12 cylinder configurations are software selectable. Output 30KV with 160 Amps of peak spark current in high energy. Duration 100uS per spark, with up to 22 degrees of duration with one spark every 1.2mS. Compatibility SmartFire is Windows 95 to XP compatible and comes with an electronic instruction manual. This document is distributed for informational purposes only. It is not to be construed as creating or becoming part of any Woodward Governor Company contractual or warranty obligation unless expressly stated in a written sales contract. Woodward 2005 All Rights Reserved. PAGE 9

10 SmartFlame Module DIO, CAN and SmartFlame modules. Larger configurations are possible with hundreds of channels. Software selectable gains allow online adjustment of the signal to support changes in operating condition. Software selectable voltages of 100V, 200V, 300V, and 400V allow for extended diagnostics. Precision Ion Sensing module Full Isolation 100kS/s, 16-bits Software selectable voltage and gain National Insturments crio back plane must be purchased separately Advanced Combustion Controls 3800 North Wilson Ave. Loveland, CO Ph: +1 (970) Fax: +1 (970) smartfire DESCRIPTION The Woodward SmartFlame module is a precision flame ionization sensing module used to read the ionization intensity in combustion applications. It provides a user selectable voltage from 100V to 400V and is available in positive and negative supply versions. The SmartFlame modules utilizes far-side sensing to ensure the best signal to noise ratio. Data is collected at a rate of 100k samples/second with a resolution of 16 bits. These modules plug in to standard National Instruments crio chassis and allow for online data acquisition and signal processing. Portable chassis may accept up to eight crio form factor modules including D/A, A/D, The National Instruments user interface (LabVIEW) for the SmartFlame Module This document is distributed for informational purposes only. It is not to be construed as creating or becoming part of any Woodward Governor Company contractual or warranty obligation unless expressly stated in a written sales contract. Woodward 2005 All Rights Reserved. PAGE 10

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12 ACTUATOR AND THROTTLE BODY SPECIFICATIONS Actuators Integrated Throttle Bodies and Actuators Travel Degrees Peak SS*** Torque ftlbs Peak TR*** Torque ftlbs Approx Slew Time Vol Dimensions L Series ProAct Digital ProAct ISC ProAct ITB Flo-Tech ITB Model 1 Model 2 Model 3 Model 4 Model 1 Model 2 Model 2 Model _ _ 75.7 x 88.4 x x 88.4 x x 5.1 x x 5.1 x x 5.1 x x 5.1 x x 5.1 x x 5.1 x x 5.1 x x d 5.0 L Series ITB 75.7 x 88.4 x mm 33mm 25mm 120mm 48mm 30mm Available Throttle Body Sizes for Various Actuators 135mm 60mm 36mm 68mm 75mm 43mm 50mm Integrated Throttle Bodies/Size Approx Output Integrated Throttle Bodies/Size Approx Output ProAct ITB-135mm ProAct ITB-120mm ProAct ITB-105mm Flo-Tech ITB- 75mm Flo-Tech ITB- 68mm Flo-Tech ITB- 60mm Flo-Tech ITB- 48mm Flo-Tech ITB- 33mm 1-2 mw For proper sizing please consult page kw - 500kw L Series ITB - 50mm L Series ITB - 45mm L Series ITB - 36mm L Series ITB - 30mm L Series ITB - 25mm 15kw -100kw For proper sizing please consult page 29. PAGE 12

13 ACTUATOR PRODUCT OVERVIEW L Series Speed Controller The Woodward L Series Integrated Engine Control System is the first engine speed control to deliver so much in a package this compact, and it can also deliver a big savings in production and field support. Since the L Series Control System is microprocessor-based, it can easily be programmed to match the operating parameters of every engine you produce. All it takes is a PC and a simple, plug-in download on your production line. With many built-in functions, this microprocessor-based speed control allows a high-volume OEM or packager to stock one part number, but implement a wide variety of engine control strategies by configuring the four auxiliary inputs at their factory. ProAct Digital Plus Actuators The ProAct Digital Plus actuator is intended to be mounted on-engine to control varying functions including (but not limited to): fuel rack positioning, timing control, throttle valve, and wastegate positioning. The actuator is effectively a positioner with an integral driver, which will accept a position command signal from another device in the system such as a speed control. The ProAct Digital Plus actuator includes an integral digital driver capable of controlling the actuator, communicating with the outside control system, and containing on-board software and intelligence to realize monitoring and customizing functions. ProAct ISC Integrated Speed Control The ProAct Integrated Speed Control (ISC) is an electric actuator with an integrated electronic driver capable of diesel or gaseous engine speed control or positioning tasks. The ProAct ISC can be mounted on-engine to control a diesel fuel rack or gaseous throttle via linkage or integrated throttle body. The ProAct ISC accepts a speed input from an MPU and can accept a position command signal from another device in the system such as an engine control module. Configured as a speed control, the ProAct ISC offers speed control with software-selectable speed set points, dynamics, fuel limiting, and start/stop behavior. Configured as a positioner, the ProAct ISC offers position control with software selectable CW/CCW operation and field calibration. PAGE 13

14 L Series Integrated Engine Speed Control 03225E DESCRIPTION The Woodward L Series Integrated Engine Control System is the first engine speed control to deliver so much in a package this compact. It can also deliver a big savings in production and field support. Since the L Series Control System is microprocessor-based, it can easily be programmed to match the operating parameters of every engine you produce. The L-Series offers speed control with software-selectable speed setpoints, dynamics, fuel limiting, and start/stop behavior. All it takes is a PC and a simple, plug-in download on your production line. With many built-in functions, this microprocessor-based speed control allows a high-volume OEM or packager to stock one part number, but implement a wide variety of engine control strategies by configuring the four auxiliary inputs at their factory. Besides the traditional bracket mount using external linkage, the L Series Control System is available in a variety of mechanical configurations, including one integrated into a rotary diesel fuel pump and one integrated with a throttle body (product spec 03223) or a throttle body and mixer (product spec 03222). The externally mounted systems can be configured for clockwise or counterclockwise (standard) shaft rotation for increasing fuel. To learn more about the new L Series integrated engine control, contact Woodward today. L Series control features: Operates fuel or air control with 0.34 N m (0.25 lb-ft) torque (60 travel range) State-of-the-art speed sensing and control algorithms Comprehensive diagnostics for easy troubleshooting End-of-line programmability simplifies inventory Optional transient smoke limiter for turbocharged diesel engines Customer configurable auxiliary inputs available on board to match your specific application Optional mounting kits for Stanadyne DB-series or Delphi DP200 & DP210 fuel injection pumps provides integrated control solution Speed setpoint adjustment using Idle/Rated1/Rated2, Raise/Lower, and external analog settings Dual sets of speed dynamics can be set by engine speed, discrete input, or even an external signal Low cost engine control Fully integrated actuator and speed control Small package greater design flexibility Suitable for gasoline, gaseous, and diesel fueled engines Microprocessorbased Tamper-resistant Easy setup and tuning using PC-based Service Tool Discrete output driver for fault indication Voltage output for throttle position indication Configurable I/O Optional CANopen communications PAGE 14

15 L Series Integrated Engine Speed Control 03225E SPECIFICATIONS Power Supply 12/24 volt system, 10 to 32 Vdc Power Consumption Reverse polarity protection, 32 W max Torque 0.34 N m (0.25 lb-ft) Dimensions (WxHxL) 75.7 x 88.4 x mm (2.98 x 3.48 x 4.38 in.) Weight 425 g (15 oz) Connector 12-pin Deutsch connector (DT06-12SA-P012) Control Characteristics Speed Input Magnetic pickup or ignition coil and Range MPU input: Hz, teeth, 1 Vrms min. IGN input: Hz, 1 20 cylinders with rated speed up to 4000 rpm Target speed: programmable Speed range: programmable Actuator Torque High-efficiency torque motor; delivers 0.34 N m (0.25 lb-ft) (60 travel range) to operate fuel or air control Steady State Fuel Type Gasoline Diesel Gaseous Speed Regulation MPU input ±0.35% ±0.25% ±0.35% Ignition input ±0.50% n/a ±0.50% Functions/Auxiliary Inputs Function Options Isochronous Speed (50 or 60 Hz); Two or Three Speed; Droop; Start Fuel Limiter; Load Sharing; Dual Dynamics; Adjustable Max Fuel Stop; Manifold Air Pressure Biased Fuel Limiter; Cold Start Timer Programming Port I/O Programmable with Windows GUI software ( ) and harness ( ) 0 5 V throttle position indication Discrete out for fault indication 4 aux inputs, configurable functions Environment Operating Temp 40 to +105 C ( 40 to +221 F) Storage Temp 40 to +125 C ( 40 to +257 F) EMC EN : Immunity for Industrial Environments EN : Emissions for Industrial Environments SAE J : Radiated Immunity (100 V/m) SAE J : Conducted Transient Immunity Pulse 5b, Suppressed Load Dump (45 V) Humidity US MIL-STD 810E, Method 507.3, Procedure III Shock MS1-40G 11ms sawtooth Vibration Random: 0.3 G2/Hz, Hz (22.1 Grms) 3 h/axis Sine: 5 G 2.5 mm peak-to-peak, Hz, 3 h/axis, 90 min dwells, 1 octave/min Thermal Shock SAE J1455, Paragraph Fluid Resistance IP56 per EN60529 Compliance CSA CE Other Technical Manual Class I, Division 2, Groups A, B, C, D T3C Compliant with EMC Directive 89/336/EEC Compliant as a component with Machinery Directive 98/37/EC Advanced Combustion Controls 3800 North Wilson Ave. Loveland, CO Ph: +1 (970) Fax: +1 (970) smartfire This document is distributed for informational purposes only. It is not to be construed as creating or becoming part of any Woodward Governor Company contractual or warranty obligation unless expressly stated in a written sales contract. Woodward 2005 All Rights Reserved. PAGE 15

16 ProAct Analog and Digital Plus Electric Actuators with Integral Driver 03231F APPLICATIONS The ProAct Analog product line is a family of electric actuators intended to be mounted on-engine to control varying functions including (but not limited to): fuel rack positioning, timing control, throttle valve, and wastegate positioning. The actuator is effectively a positioner with an integral driver, which will accept a position command signal from another device in the system such as a speed control. In addition, the ProAct Digital Plus actuators include an integral digital driver capable of controlling the actuator, communicating with the outside control system, and containing on-board software and intelligence to realize monitoring and customizing functions. DESCRIPTION The actuators are designed to be base- or flange-mounted (Model IV is basemounted only) in an on-engine environment and can therefore withstand high levels of vibration and temperature extremes. They all have a serrated tooth terminal shaft, and an optional rotation scale and indicator are available for visible travel detection. The actuators accept analog or PWM position command signals. In addition, the Digital Plus driver accepts CAN position command signals and can be configured for redundant command signals. It monitors all available internal and external signals, and annunciates any detected faults through a discrete output. An analog output provides actual position indication, and a discrete input is available to remotely shut down the actuator. Additional features of the Digital Plus driver include on-line and off-line diagnostics, current limiting based on driver electronics temperature, CAN communications, and service port communications. The Digital Plus driver is field programmable, allowing a single design to be used in many different applications. It must be configured and calibrated to the specific engine with a personal computer (PC) and a Woodward Watch Window Service Tool that communicates serially to the driver via RS-232 using Woodward s DDE ServLink protocol. Watch Window Standard can be ordered from Woodward on a CD-ROM (part number ), or it can be downloaded from the Woodward website ( Data files for subsequent applications of the same engine model can be downloaded offengine. The ProAct Analog actuator/driver can be configured without a service tool. Refer to manual for more detailed information on the ProAct Digital Plus actuator, and to manual for more information on the ProAct Analog. Extremely fast, bidirectional actuator, electronically positioned in both directions All-electric actuator requires no drive or hydraulic supply Integral driver compatible with broad range of control systems 75 (±2 ) rotary output allows direct coupling to butterfly, eliminating linkage Multiple sizes to fit broad range of applications Digital Plus: Single or redundant position command signals Configurable parameters to tailor to varied applications CAN communications Advanced Diagnostics PAGE 16

17 ProAct Analog and Digital Plus Electric Actuators with Integral Driver 03231F GENERAL SPECIFICATIONS Minimum Work Output Maximum Input Power Maximum Current Actuator Model Model I Part Number Weight Transient Steady State Transient Continuous Transient Steady State Analog Digital Plus 10.5 kg (24 lbs) 11 kg (25 lbs) 3.4 J 2.5 ft-lbs 1.7 J 1.25 ft-lbs 67 W 19 W 3.7 A 1 A Model II Analog Digital Plus 10.5 kg (24 lbs) 11 kg (25 lbs) 7 J 5 ft-lbs 3.4 J 2.5 ft-lbs 251 W 65 W 14 A 4 A Model III Digital Plus 15 kg (32 lbs) 14 J 10 ft-lbs Model IV Digital Plus 24 kg (52 lbs) 27 J 20 ft-lbs 7 J 5 ft-lbs 14J 10 ft-lbs 282 W 73 W 15.6 A 4 A 370 W 100 W 20.6 A 5.6 A END USER I/O DESCRIPTION Analog Digital Plus Power Input Vdc Vdc with out-of-range diagnostics Command Input PWM: 7 32 V, Hz Analog: ma, 4 20 ma, & Vdc Position Feedback Output 0.5 Vdc and 4.5 Vdc corresponds to full CCW and CW, respectively PWM: 7 32 V, 100 to 3000 Hz Analog: ma or 4 20 ma CAN 4 ma and 20 ma corresponds to 0% and 100% actuator position Discrete Inputs Not Applicable Low Power standby mode Four CAN address combinations Discrete Output Not Applicable Normally ON turns OFF to indicate a detected fault RS-232 Serial Communications CAN 2.0B Serial Communications (optional) Not Applicable Not Applicable 9-pin sub-d male connector for connection to PC Service Tool Complies with SAE J1939 but uses proprietary group extensions. Supports position command signal and monitoring of all shutdown and alarm conditions as well as some system variables. ENVIRONMENTAL SPECIFICATIONS Operating Temperature Limits Storage Temp Vibration Qualification Test Shock Qualification Test Acceptable Range or Qualification Condition Analog: 40 to +74 C. Digital Plus: 40 to +85 C. Under all conditions the Temperature Monitoring Zone must remain below 90 C. 40 to +125 C, unpowered. Comments See Mechanical Installation section of manual for discussion of this specification item. Sine: 3.2 mm peak-to-peak for Hz, 10 G for Hz. Random: 0.01 G2/Hz at 10 Hz, 0.10 at 100 Hz, 0.10 at 1000 Hz, 0.05 at 2000 Hz (12.79 Grms) 3 hours per axis. MS1 40G 11ms sawtooth. Ingress Protection IP56 per EN 60529:1992. Humidity Qualification Test Chemical Resistance 60 C, 95% RH for five days at one cycle per day. The actuator uses materials proven capable of withstanding normal engine environment chemicals per SAE J1455, such as diesel fuel, engine oil, and antifreeze. PAGE 17

18 ProAct Analog and Digital Plus Electric Actuators with Integral Driver 03231F ProAct Analog Outline Drawing (Do not use for construction.) ProAct Digital Plus Outline Drawing (Do not use for construction.) PAGE 18

19 ProAct Analog and Digital Plus Electric Actuators with Integral Driver 03231F SPECIFICATIONS Max Slew Rate > 1000 degrees/second > 18.5 rad/s (10% to 90% travel) Position Feedback Accuracy Analog ±5% of full scale from 40 to +90 C Digital Plus < ±1.5% of full stroke at 25 C after calibration and ±1.5% linearity < 400 ppm/ C, maximum after calibration Position Feedback Linearity Digital Plus < ±1.5% of full stroke at 25 C after calibration Position Feedback Repeatability Digital Plus < ±1.5% of full stroke at 25 C after calibration CERTIFICATIONS, AGENCY LISTINGS, AND REGULATORY COMPLIANCE European Compliance for CE Mark EMC Directive: Declared to 89/336/EEC COUNCIL DIREC- TIVE of 03 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility. Other European Compliance Machinery Directive: Compliance as a component with 98/37/ EC COUNCIL DIRECTIVE of 23 July 1998 on the approximation of the laws of the Member States relating to machinery. Agency Listings CSA and UL/cUL for ordinary locations (Digital Plus only) CSA Class I, Div 2 component listing (standard with Analog; optional upgrade with Digital Plus) Marine Type Approved by Lloyds Register of Shipping for ENV1, ENV2, ENV3, and ENV4 (Digital Plus only) CUSTOMER ELECTRICAL CONNECTIONS ProAct Analog The standard actuator is equipped with a 7-pin MS-style connector. ProAct Digital Plus The standard actuator is designed with a blank cover for use with a gland fitting or a custom connector to be supplied by the customer. All inputs and outputs to the ProAct actuator are accessed beneath the end cover, which is fastened with 6 M4x10 mm screws. Input power is connected to size M4 screws, and the wires must be terminated with insulated spade or ring lugs. The I/O terminal blocks are screwless cage-clamp-style blocks that accept wires from mm2 (24 12 AWG) wire. Actuators with an MS-style connector mounted as an option on the end cover are also available. For OEMs, other factoryinstalled connectors may also be considered. Technical Manual Analog Digital Plus Advanced Combustion Controls 3800 North Wilson Ave. Loveland, CO Ph: +1 (970) Fax: +1 (970) smartfire This document is distributed for informational purposes only. It is not to be construed as creating or becoming part of any Woodward Governor Company contractual or warranty obligation unless expressly stated in a written sales contract. Woodward 2005 All Rights Reserved. PAGE 19

20 ProAct ISC Integrated Speed Control Electric Actuator with Integral Speed Control or Position Driver APPLICATIONS The ProAct Integrated Speed Control (ISC) is an electric actuator with an integrated electronic driver capable of diesel or gaseous engine speed control or positioning tasks. The ProAct ISC can be mounted on-engine to control a diesel fuel rack or gaseous throttle via linkage or integrated throttle body. The ProAct ISC accepts a speed input from an MPU and can accept a position command signal from another device in the system such as an engine control module. Configured as a speed control, the ProAct ISC offers speed control with softwareselectable speed set points, dynamics, fuel limiting, and start/stop behavior. Configured as a positioner, the ProAct ISC offers position control with software selectable CW/CCW operation and field calibration. DESCRIPTION The ProAct ISC can be base or flange mounted on-engine, and will withstand high levels of vibration and temperature. The output shaft is a serrated tooth shaft. Two levels of output torque are available. The ProAct ISC will also mount directly to Woodward integrated throttle bodies. The control accepts a speed input signal from a variable reluctance speed sensor, commonly called an MPU. The control may also be user-configured as a positioner accepting an analog position command signal. Future options will include a CAN Open communication capability. The ProAct ISC offers a wide variety of speed control features: Dynamics settings, dual rated speed setting, idle/ rated speed setting, raise or lower speed modifier, analog input speed modifier, analog raise and lower speed modifier, droop, dual dynamics, analog outputs, and discrete outputs. The control also allows isochronous load sharing, and monitors key internal and external signals, and annunciates any detected faults through a discrete output. An analog output provides actual position indication, and a discrete input is available to remotely shut down the control. Additional features of the ProAct ISC include on-line and off-line diagnostics, current limiting based on driver electronics temperature, and service port communications. The control is field programmable, allowing a single design to be used in many different applications. It must be configured and calibrated to the specific engine with a personal computer (PC) and the ProAct ISC Service Tool that communicates serially to the control via RS-232 using Woodward s DDE ServLink protocol. The ProAct ISC Service Tool can be downloaded from the Woodward website ( Refer to manual for more detailed information on the ProAct Integrated Speed Control. Extremely fast, bidirectional electric actuator, electronically positioned in both directions All-electric actuator requires no drive or hydraulic supply Integral driver compatible of recip engine speed control or positioning tasks 75 (±2 ) rotary output allows direct coupling to butterfly, eliminating linkage Two sizes to fit broad range of applications Configurable parameters to tailor to varied applications Advanced Diagnostics PAGE 20

21 ProAct ISC Integrated Speed Control Electric Actuator with Integral Speed Control or Position Driver GENERAL SPECIFICATIONS Minimum Work Output Maximum Input Power Maximum Current Actuator Model Typical Part Number Model I kg 24 lbs Model II kg 24 lbs Weight Transient Steady State Transient Continuous Transient Steady State 2.5 J 22 in-lb 5 J 44 in-lb 1.25 J 11 in-lb 2.5 J 22 in-lb 63 W 36 W 3.5 A 2 A 198 W 63 W 11 A 3.5 A END USER I/O DESCRIPTION Speed Control Configuration Positioner Configuration Power Input Vdc Vdc Command Input MPU (Magnetic Pickup) frequency input Vrms khz Analog: 4 20 ma, 0 5Vdc, ±3 Vdc Position Feedback Output Available, see Analog Output below. 4 ma and 20 ma corresponds to 0% and 100% actuator position. Analog Inputs 4 20 ma, 0 5 Vdc, ±3 Vdc See Command Input Analog Outputs 1 Available ma, 450 Ω load 1 Available ma, 450 Ω load Available, see Analog Output below. 4 ma and 20 ma corresponds to 0% and 100% actuator position. Discrete Inputs 5 Available. Software selectable High / Low or Active Open / Closed 5 Available. Software selectable High / Low or Active Open / Closed Discrete Output 1 Available. Low side switch. 0.5 A 1 Available. Low side switch. 0.5 A RS-232 Serial Communications Used for Service Tool Communications. Integral with main connector. CAN 2.0B Serial Communications Available for Boost Fuel Limit function Hardware installed, future availability ENVIRONMENTAL SPECIFICATIONS Operating Temperature Limits 40 to +85 C Storage Temperature Vibration Qualification Test Thermal Shock Qualification Test Acceptable Range or Qualification Condition 40 to +125 C, unpowered Ingress Protection IP56 per EN 60529:1992. Humidity Qualification Test Chemical Resistance Used for Service Tool Communications. Integral with main connector. RV2: US MIL -STD-202F, procedure 214A: 0.1 G 2 / Hz, Hz, 3 hr /axis, 12.8 Grms Swept Sine 5 25 Hz, ±1.6 mm, Hz ±4.0 G Reference: SAE J1455, Paragraph cycles from 40 oc to +125 oc. Unit unpowered. 60 C, 95% RH for five days at one cycle per day. The actuator uses materials proven capable of withstanding normal engine environment chemicals per SAE J1455, such as diesel fuel, engine oil, and antifreeze. PAGE 21

22 ProAct ISC Integrated Speed Control Electric Actuator with Integral Speed Control or Position Driver ProAct Integrated Speed Control (Do not use for construction.) PAGE 22

23 ProAct ISC Integrated Speed Control Electric Actuator with Integral Speed Control or Position Driver ProAct Integrated Speed Control (Do not use for construction.) Advanced Combustion Controls 3800 North Wilson Ave. Loveland, CO Ph: +1 (970) Fax: +1 (970) smartfire SPECIFICATIONS Max Slew Rate > 1000 degrees/second > 18.5 rad/s (10% to 90% travel) Position Control Accuracy ±3% of full scale Steady State Speed Band 0.5% of rated speed Technical Manual REGULATORY COMPLIANCE CE Compliance: Compliant with EMC and Machinery Directives Agency Listings: CSA Class 1, Division 2, Groups A, B, C, and D per CSA for Canada and US nonhazardous locations only. CUSTOMER ELECTRICAL CONNECTIONS ProAct ISC The ProAct ISC is equipped with a 24 pin MS-style connector. This document is distributed for informational purposes only. It is not to be construed as creating or becoming part of any Woodward Governor Company contractual or warranty obligation unless expressly stated in a written sales contract. Woodward 2005 All Rights Reserved. PAGE 23

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25 THROTTLE BODY PRODUCT OVERVIEW L Series ITB Integrated Throttle Body The L Series ITB is a member of Woodward s Integrated Throttle Body family. Several throttle body size configurations (between 25 and 50 mm) are integrated with speed control or actuator options for use on gaseous fueled industrial engines between 5 and 100 kw (7 and 134 hp). Applications include automotive, power generation, refrigeration units, pumps, irrigation, mobile industrial, and gas trim valves. The L Series ITB integrated throttle body and speed control or actuator provides a building block approach to total engine management. This modular design consists of a die-cast aluminum throttle body plus a fully programmable integrated digital speed control and bi-directional actuator. Flo-Tech ITB Integrated Throttle Body/Actuator The Flo-Tech ITB integrated throttle body and actuator is designed for direct replacement of manual throttle bodies, and is designed with flow shaping to assist in engine idle stability. The throttle body will provide equivalent maximum flow rates of standard butterfly throttle bodies of the same diameter. The system contains a return spring to fully comply with DOT specifications. Determination of the proper size requires a knowledge of the absolute pressure drops across the valve, the expected temperature of the gaseous media flowing, and the density of the gas. Cv (volume coefficients) are provided to determine the flow vs. angle. For initial testing, a valve body diameter similar to the one typically used on the application can be used. The Flo-Tech integrated actuator/throttle body requires no actuator or linkage. ProAct ITB Integrated Throttle Body The ProAct ITB integrated throttle body includes 107 mm, 120 mm, and 135 mm bore sizes, and is designed for use with engines in the 1-2 MW range. These large ITB units are made to couple directly to Woodward s ProAct actuators (an electromagnetic, 75-degree device), and therefore alleviate the problems associated with linkages on gas engines, such as non-linearity and wear. This direct combination of throttle and actuator results in excellent low-load stability and transient characteristics, and requires no hydraulics, pneumatics, or governor gear train. PAGE 25

26 L Series ITB Integrated Throttle Body and Speed Control or Actuator Overspeed/underspeed protection Remote speed setting Three speed select Error relay driver Integrated, bi-directional actuator or OEM-configurable speed control APPLICATIONS The L Series ITB is a member of Woodward s Integrated Throttle Body family. Several throttle body size configurations (between 25 and 50 mm) are integrated with speed control or actuator options for use on gaseous fueled industrial engines between 5 and 100 kw (7 and 134 hp). Applications include power generation, refrigeration units, pumps, irrigation, mobile industrial, and gas trim valves. The integrated throttle body incorporates the proven Woodward L Series speed control or L Series actuator, which operates the throttle plate. The L Series ITB Speed Control can be programmed via the RS-232 port of a personal computer to a variety of configurations, as follows: Isochronous speed control Droop Auxiliary input Dual dynamics Adjustable ramp time Self-tuning gain The L Series Actuator comes in two basic configurations with or without on-board final drivers. The onboard driver version accepts a 7 32 Vdc, Hz PWM position command signal. The version without drivers brings the actuator coil (4 25 C, Hz) leads directly out to the Deutsch connector. The L Series Actuator also has an optional, integral 0 5 Vdc throttle position feedback signal. DESCRIPTION The L Series ITB integrated throttle body and speed control or actuator provides a building block approach to total engine management. This modular design consists of a die-cast aluminum throttle body plus a fully programmable integrated digital speed control and bi-directional actuator. The throttle body incorporates a corrosionprotected, plated steel shaft, plate, and a sealed ball-bearing design for durability and long life. An internal throttle return spring is standard to close the throttle in the event of power failure. The modular design of the L Series ITB system reduces total engine assembly cost, eliminates external linkages, lowers inventory and part number proliferation. The programmable controller offers security to your configuration. The L Series ITB speed control is compatible with Woodward s venturi-style mixer and other brands of gas mixers using suitable adapters (see L Series product specification for speed control details and operating parameters). Eliminates external linkages Reduces total engine assembly costs Can be used in turbocharged applications with throttle pressure higher than ambient Optional PWM input positioner model with integral position feedback Sealed ballbearing throttle body design Full range of bore sizes available: 25, 30, 36, 43, 50 mm Tamperproof End-of-line programmable speed control PAGE 26

27 L Series ITB Integrated Throttle Body and Speed Control or Actuator SPECIFICATIONS Representative Drawing of 30 mm L Series ITB Control (Do not use for construction) Representative Drawing of 50 mm L Series ITB Control (Do not use for construction) Advanced Combustion Controls 3800 North Wilson Ave. Loveland, CO Ph: +1 (970) Fax: +1 (970) smartfire Technical Manual This document is distributed for informational purposes only. It is not to be construed as creating or becoming part of any Woodward Governor Company contractual or warranty obligation unless expressly stated in a written sales contract. Woodward 2005 All Rights Reserved. PAGE 27

28 Flo-Tech ITB Integrated Throttle Body and Actuator 04140B APPLICATIONS The Flo-Tech ITB integrated throttle body and actuator is designed with flow shaping to assist in engine idle stability. The throttle body will provide equivalent maximum flow rates of standard butterfly throttle bodies of the same diameter. The system contains a return spring to fully comply with DOT specifications. Determination of the proper size requires a knowledge of the absolute pressure drops across the valve, the expected temperature of the gaseous media flowing, and the density of the gas. Cv (volume coefficients) are provided to determine the flow vs. angle. For initial testing a valve body diameter similar to the one typically used on the application can be used. The Flo-Tech ITB is designed for direct replacement of manual throttle bodies. It requires no actuator or linkage. DESCRIPTION The Flo-Tech family of electrically actuated throttles/valves controls flow. The flow is a function of throttle position and pressure drop. The throttle position is proportional to the position command signal. The Flo-Tech ITB can be made with 33, 48, 60, 68, and 75 mm bore sizes for various applications. Command input options come in PWM, 0 5 Vdc, 4 20 ma, and ma. Position feedback output signal will vary from 0.5 ± 0.1 volts to 4.5 ± 0.1 volts nominal at the min and max actuator position respectively. The PWM command input version will return to minimum actuator position with a command of greater than 95% duty cycle. The Flo-Tech actuator requires a power supply of 9 32 Vdc. The supply must be capable of supplying a sustained 25 watts at steady-state and 50 watts for transient state conditions for at least 0.25 second. No linkage or couplings Cost-effective and highly efficient Extremely low maintenance product Small size for easy installation Conveniently integrated electronics Includes returnspring to fully comply with DOT specs Versatile 12 or 24 Vdc operation PAGE 28

29 Flo-Tech ITB Integrated Throttle Body and Actuator 04140B INSTALLATION The Flo-Tech ITB integrated throttle body and actuator may be mounted in any position. Both mounting flanges on the throttle body have four 10 mm through-holes in a square, 74 mm pattern. The base of the unit has an optional bolt pattern that can be used for mounting support. It uses 4 M8x0.125 bolts in an 88.9 mm square pattern. The connector to the Flo-Tech actuator is a Packard Electric male connector. The mating connector is a Packard female connector (Woodward p/n ) with seals and pins. Different connectors are available but not standard. Please contact the factory if you would like to use a different connector. Cv for Standard Flo-Tech Units DETERMINING PROPER VALVE SIZE Proper valve size can be determined by using the following equation: Cv = Q * * (G * T / ((P1 P2) * K)) ^ 0.5 Where: Q = Flow (PPH) G = Specific gravity of fluid ( = 1.0 for air) T = Absolute temperature (460 + F) P1 = Inlet pressure (psia) P2 = Discharge pressure (psia) K = P2 if P1 P2 is less than 10% of P1 = P1 if P1 P2 is 25% or more of P1 = (P1+P2)/2 if P1 P2 is in between 10 & 25% P2 must be Greater than.53 * P1 (or flow becomes choked). Cv (flow coefficient) should be calculated for the minimum and maximum flows expected (at 50 ) on the application. Cv (Flow Coefficient) Angle 33mm 48mm 60mm 68mm 75mm COMMAND VS. POSITION FEEDBACK/THROTTLE POSITION The actuator is designed to provide 0.5 volts output at zero position, and 4.5 volts at full position. Feedback signals of 0 or 5 Vdc indicate faults. The PWM input signal greater than 95% causes the output to go to zero position. Thus, if the PWM fails to 5 Vdc, the unit fails in a safe direction. Temperature drift from 25 C to 105 C or from 25 C to 40 C causes the internal sensor to shift calibration. The effect of this is that the output position does not start to move until 0.8 Vdc and gets to the full position at 4.2 Vdc at 40 and 105 C. The output position signal will still track the command signal. This means that although the OEM cannot use this signal for true position, the OEM can still use this signal to verify that the Flo-Tech unit is responding to the command signal. PAGE 29

30 Flo-Tech ITB Integrated Throttle Body and Actuator 04140B Outline for Flo-Tech 33, 48, 60, and 68 mm Bores (Do not use for construction.) Outline for Flo-Tech 75 mm Bore (Do not use for construction.) CAUTION: Flo-Tech throttle body does not completely shut off. A separate shutdown is required. PAGE 30

31 Flo-Tech ITB Integrated Throttle Body and Actuator 04140B SPECIFICATIONS Weight 6 kg (13.2 lbs) Operating Temperature 40 to +105 C ( 40 to +221 F) Housing Temperature Storage Temperature 55 to +105 C ( 67 to +221 F) Vibration Sine Sweep Random Temp & Humidity Technical Manual MS 810C, M514.2 Curve J (Mod) MS 202F, Method 214A, Cond. G SAE J1455 Inputs Power Supply 9 to 32 Vdc (12/24 Vdc nominal) 10 A fuse in series with the input power. Must be able to supply 50 W for 0.25 second in transient conditions and 25 W continuous for steady state conditions. Position Command Using the max Cv number, and the chart below, select the Flo-Tech unit which most closely matches at 50 angle. Verify that the minimum required Cv is above the Flo-Tech unit s Cv ensuring the engine will reach idle when the Flo-Tech unit closes. Advanced Combustion Controls 3800 North Wilson Ave. Loveland, CO Ph: +1 (970) Fax: +1 (970) smartfire Input Command Input Range Input Impedance Other Commands PWM 10-90% ka PWM Frequency Hz Amplitude 4 32 Vdc 10 bit resolution 0-5 Vdc Vdc ka 4-20 ma 5 19 ma 249 A ma ma 35.7 A OUTPUTS PART NUMBERS Input Command Input Range Position Feedback Output 23 ºC Position Feedback Outback 40 & 105 ºC PWM 10 90% ± 0.1 Vdc ± 0.2 Vdc Vdc Vdc ± 0.1 Vdc ± 0.2 Vdc ma 5 19 ma ± 0.1 Vdc ± 0.2 Vdc ma ma ± 0.1 Vdc ± 0.2 Vdc 0 70 Valve Size (mm) Input Part No PWM 4-20 ma PWM 4-20 ma ma PWM 0-5 Vdc Valve Size (mm) Input Part No ma PWM 0-5 Vdc 4-20 ma ma PWM Nominal Actuator Range This document is distributed for informational purposes only. It is not to be construed as creating or becoming part of any Woodward Governor Company contractual or warranty obligation unless expressly stated in a written sales contract. Woodward 2005 All Rights Reserved. PAGE 31

32 ProAct ITB Integrated Actuator and Throttle Body for Large Bores (105, 120, 135 mm) 03305B No linkage or couplings Cost effective and highly efficient Low maintenance Requires no hydraulics, pneumatics, or governor gear train Long lasting, easy to install throttle option APPLICATIONS The ProAct ITB integrated actuator and throttle body is designed to throttle air or air/fuel for gaseous engines. This system is designed for direct replacement of traditional throttle valves, and requires no linkage between valve and actuator. The three sizes are designed to cover a wide range of engines and should be selected using the sizing procedure described inside this specification. DESCRIPTION The PoAct Integrated Throttle Bodies (ProAct ITBs) are butterfly valves electrically-actuated by ProAct Analog and ProAct Digital Plus actuators to control flow output. With bore sizes of 105 mm, 120 mm, and 135 mm, these ProAct ITBs are designed for use with engines in the 1 2 MW range. The ProAct actuators are electro-magnetic, 75 degree-of-travel devices, and therefore alleviate the problems associated with linkages on gas engines (such as setup, non-linearity, and wear). This direct combination of throttle and actuator results in excellent stability and transient characteristics, and requires no hydraulics, pneumatics, or governor gear train. Therefore, you end up with an efficient, long lasting, and easily-installed throttle option. PAGE 32

33 ProAct ITB Integrated Actuator and Throttle Body for Large Bores (105, 120, 135 mm) 03305B DETERMINING THE PROPER VALVE SIZE The proper size valve can be determined using the equation below. The required Cv (flow coefficient) should be calculated for both the minimum and maximum flows expected on the application. This design allows for a nominal travel of 75 degrees of rotation. Using the graph and table below, select the closest valve that has a Cv equal to or greater than the calculated maximum flow value at approximately 80% opening (60 degrees) to ensure reasonable flow margin. Also, check that the particular valve s minimum Cv listed below is less than the minimum calculated Cv for good low idle performance. For further assistance, consult the Woodward engineering department. Cv vs Angle for ProAct ITBs Cv := Q P1.Sg (T + 460). P1. Sg P1 P2 where: Cv = Flow Coefficient Q = Mass Flow (PPH [pounds/hour]) [1 pound = 0.45 kg] Sg = Specific Gravity of Gas (use 1.0 for air) T1 = Upstream Gas Temperature ( F) [ F = 1.8 * C +32] P1 = Inlet Pressure (psia) [1 psi = kpa = bar] P2 = Downstream Pressure (psia) Note: P2 must be greater than * P1 or flow becomes choked. If P2 is less than * P1, then use P2= * P1. Cv (Flow Coefficient) Plate Angle 105 mm 120 mm 135 mm Note: These flow coefficients were determined using the test setup described in ANSI/ISA-S Control Valve Capacity Test Procedure. PAGE 33

34 ProAct ITB Integrated Actuator and Throttle Body for Large Bores (105, 120, 135 mm) 03305B ProAct ITB 105 with ProAct Digital Plus Model II (Also available with ProAct Analog.) (Do not use for construction.) ProAct ITB 120 with ProAct Digital Plus Model II (Also available with ProAct Analog.) (Do not use for construction.) PAGE 34

35 ProAct ITB Integrated Actuator and Throttle Body for Large Bores (105, 120, 135 mm) 03305B ProAct ITB 135 with ProAct Digital Plus Model III (Do not use for construction.) Advanced Combustion Controls 3800 North Wilson Ave. Loveland, CO Ph: +1 (970) Fax: +1 (970) smartfire SPECIFICATIONS Operating Temperature Range Digital Plus 40 to +85 C ( 40 to +185 F) Analog 40 to +74 C ( 40 to +165 F) Storage Temp Range 55 to +125 C ( 67 to +257 F) Vibration Qualification Woodward RV2 (0.1 G2/Hz Random, Test Spec Hz, 12.8 Grms 3 hours per axis) Shock Qualification 40 G, 11 ms sawtooth pulse Test Spec Weight See table under mounting section of manual Nominal Diameter 135 mm (5.3 inches), 120 mm (4.7 inches), or 105 mm (4.1 inches) Maximum Working 60 psig (414 kpa/4.1 bar) Pressure Technical Manual Regulatory Compliance Note: Refer to the ProAct Digital Plus manual (26112) or ProAct Analog manual (26147) for actuator compliance. European Compliance for CE Marking: Pressure Equipment Directive Certified to Pressure Equipment Directive 97/23/EC of 29 May 1997 on the approximation of the laws of the Member States concerning pressure equipment, Category II Other European Compliance: Compliance with the following European Directive does not qualify this product for application of the CE Marking: Machinery Directive Compliance as a component with 98/37/EC COUNCIL DIRECTIVE of 23 July 1998 on the approximation of the laws of the Member States relating to machinery. This document is distributed for informational purposes only. It is not to be construed as creating or becoming part of any Woodward Governor Company contractual or warranty obligation unless expressly stated in a written sales contract. Woodward 2005 All Rights Reserved. PAGE 35