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

Woodward is the worlds largest independent designer, manufacturer, and service provider of energy control solutions for aircraft engines, industrial engines and turbines, power generation, and mobile industrial equipment. The companys innovative control, fuel delivery, and combustion systems help customers worldwide operate cleaner, more reliable, and cost effective equipment. Good control solutions are more than just components and systems. Good solutions also 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 todays engines and equipment operate more cleanly, reliably and efciently. Woodward has a full range of products and control system solutions based on four key technologies fuel and air delivery, combustion control, electronic controls and software, and systems integration. With Woodwards fully integrated control system architecture, control system costs can be signicantly reduced while performance and network communications capabilities are enhanced. This catalog will focus on the Woodward product lines of actuators, throttle bodies and ignition systems that are relevant to the automotive, industrial and testing markets.
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WOODWARD PRODUCT FAMILY OVERVIEW
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IGNITION AND ION SENSING PRODUCT OVERVIEW

SmartFire Instrumentation Ignition The SmartFire ignition controller is the state of the art in combustion electronics. SmartFire and its combustion analysis software, WinFire, can be used to gather combustion data crucial for engine development and tuning with no modications to the combustion chamber. SmartFire is the rst commercially available ignition and engine diagnostic system to fully utilize ionization feedback. SmartFlame Module The SmartFlame module was developed to meet the need of researchers experimenting with ion currents. It provides a simple and convenient method of creating an ion bias voltage. Since the module is totally isolated it is easy to hook up and install. This module is used in conjunction with standard off the shelf NI hardware. It allows for real time acquisition and processing of ion signals. This platform can communicate the data either digitally over a network or analog via any of the many off the shelf modules. The NI systems that hold these modules range in size from 4-module portable systems to large rack mount systems capable of holding hundreds of systems.
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SmartFire Instrumentation Ignition
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 systems 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 agging on diesel engines, closed loop injection timing control is possible with SmartFire. The system is also able to improve cold startability of diesel engines compared to traditional glow plugs. The SmartFire system is able to provide feedback to control fuel injection and ignition timing on an individual cylinder basis. SmartFire uses ionization feedback to allow the engine builder to dial in the maximum horsepower for each individual cylinder. The SmartFire system includes a PC interface, which allows the operator to view the ionization waveforms of each cylinder in real time. The system can re and monitor up to 12 cylinders.
Rapid engine calibration Ion sensing through the tip of the sparkplugs NO DRILLING HOLES Knock detection Misre Detection for OBD II Misre Prevention Quicker integration Can be installed and running in as little as 3 hours Runs on Windows 95/98/NT/XP
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 misres. When misres occur SmartFire uses closed loop re-strike to re-ignite the cylinder to prevent combustible mixtures from escaping the combustion chamber. SmartFire detects every occurrence of pre-ignition in the cylinder this feature is not available with conventional acoustic systems. SmartFire makes it possible to calibrate engines using misre detection and prevention through the tip of the sparkplug without drilling holes.
Knock and misre displayed on PC software
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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 misre detection in a real time format directly through the spark plug, with no extra holes to drill. SmartFire can analyze ionization from any type of fuel. Compatible with any engine the system provides an excellent return on investment. SmartFires real time display is a useful tool for realtime engine development and diagnostics. Capable of data logging on Dyno and during in car transient testing. SmartFire eliminates drilling of any extra holes in engine to get good combustion information. SmartFire delivers a start of combustion ag for diesel and HCCI engines. SmartFire with its ionization feedback is the ignition technology of the future. Peak Power Optimization individual cylinder readings make tuning much more efcient and effective; resulting in maximum performance from your engine!
SmartFire Monitoring Station Dyno Monitoring Station
Advanced Combustion Controls
3800 North Wilson Ave. Loveland, CO 80538 Ph: +1 (970) 962-7517 Fax: +1 (970) 962-7515 www.woodward.com/ smartfire www.woodward.com
SPECIFICATIONS
Input 12 or 24 Volts. Cylinder Congurations 1 through 12 cylinder congurations 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.
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SmartFlame Module
DIO, CAN and SmartFlame modules. Larger congurations 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
DESCRIPTION
The Woodward SmartFlame module is a precision ame ionization sensing module used to read the ionization intensity in combustion applications. It provides a user selectable voltage from 100V to 400V and is available in positive and negative supply versions. The SmartFlame modules utilizes far-side sensing to ensure the best signal to noise ratio. Data is collected at a rate of 100k samples/second with a resolution of 16 bits. These modules plug in to standard National Instruments cRIO chassis and allow for online data acquisition and signal processing. Portable chassis may accept up to eight cRIO form factor modules including D/A, A/D, The National Instruments user interface (LabVIEW) for the SmartFlame Module
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ACTUATOR AND THROTTLE BODY SPECIFICATIONS

Actuators L Series ProAct Digital
Model 1 Model 2 Model 3 Model 4
Integrated Throttle Bodies and Actuators ProAct ISC

Model 1 Model 2
ProAct ITB
Model 2 Model 3
Flo-Tech ITB 75 5 10 80 5.26 x 5.1 x 4.7 70 1.1 2.2 80 2.38 x d 5.0 33mm 48mm 135mm 60mm 68mm 75mm
L Series ITB 60 .25 ___ ___ 75.7 x 88.4 x 111.3 25mm 30mm 36mm 43mm 50mm
Travel Degrees Peak SS*** Torque ftLbs Peak TR*** Torque ftLbs Approx Slew Time Vol Dimensions
60 .25 ___ ___ 75.7 x 88.4 x 111.3
75 1.25 2.5 80 75.7 x 88.4 x 111.3
75 2.5 5 80 3.8 x 5.1 x 4.7
75 5 10 80 5.26 x 5.1 x 4.7
75 10 20 80 8.2 x 5.1 x 4.7
75 1.25 2.5 80 3.8 x 5.1 x 4.7
75 2.5 5 80 3.8 x 5.1 x 4.7
75 2.5 5 80 3.8 x 5.1 x 4.7 105mm 120mm
Available Throttle Body Sizes for Various Actuators
Integrated Throttle Bodies/Size 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
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Approx Output 1-2 mw For proper sizing please consult page 29.
Integrated Throttle Bodies/Size L Series ITB - 50mm L Series ITB - 45mm L Series ITB - 36mm L Series ITB - 30mm L Series ITB - 25mm
Approx Output 15kw -100kw For proper sizing please consult page 29.
25kw - 500kw
ACTUATOR PRODUCT OVERVIEW

L Series Speed Controller The Woodward L Series Integrated Engine Control System is the rst engine speed control to deliver so much in a package this compact, and it can also deliver a big savings in production and eld support. Since the L Series Control System is microprocessor-based, it can easily be programmed to match the operating parameters of every engine you produce. All it takes is a PC and a simple, plug-in download on your production line. With many built-in functions, this microprocessor-based speed control allows a high-volume OEM or packager to stock one part number, but implement a wide variety of engine control strategies by conguring the four auxiliary inputs at their factory. ProAct Digital Plus Actuators The ProAct Digital Plus actuator is intended to be mounted on-engine to control varying functions including (but not limited to): fuel rack positioning, timing control, throttle valve, and wastegate positioning. The actuator is effectively a positioner with an integral driver, which will accept a position command signal from another device in the system such as a speed control. The ProAct Digital Plus actuator includes an integral digital driver capable of controlling the actuator, communicating with the outside control system, and containing on-board software and intelligence to realize monitoring and customizing functions. ProAct ISC Integrated Speed Control The ProAct Integrated Speed Control (ISC) is an electric actuator with an integrated electronic driver capable of diesel or gaseous engine speed control or positioning tasks. The ProAct ISC can be mounted on-engine to control a diesel fuel rack or gaseous throttle via linkage or integrated throttle body. The ProAct ISC accepts a speed input from an MPU and can accept a position command signal from another device in the system such as an engine control module. Congured as a speed control, the ProAct ISC offers speed control with software-selectable speed set points, dynamics, fuel limiting, and start/stop behavior. Congured as a positioner, the ProAct ISC offers position control with software selectable CW/CCW operation and eld calibration.
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L Series Integrated Engine Speed Control
PRODUCT SPECIFICATION
03225E
Low cost engine control Fully integrated actuator and speed control Small package greater design exibility Suitable for gasoline, gaseous, and diesel fueled engines Microprocessorbased Tamper-resistant Easy setup and tuning using PC-based Service Tool Discrete output driver for fault indication Voltage output for throttle position indication Congurable I/O Optional CANopen communications
Besides the traditional bracket mount using external linkage, the L Series Control System is available in a variety of mechanical congurations, including one integrated into a rotary diesel fuel pump and one integrated with a throttle body (product spec 03223) or a throttle body and mixer (product spec 03222). The externally mounted systems can be congured for clockwise or counterclockwise (standard) shaft rotation for increasing fuel. To learn more about the new L Series integrated engine control, contact Woodward today. L Series control features: Operates fuel or air control with 0.34 N m (0.25 lb-ft) torque (60 travel range) State-of-the-art speed sensing and control algorithms Comprehensive diagnostics for easy troubleshooting End-of-line programmability simplies inventory
DESCRIPTION
The Woodward L Series Integrated Engine Control System is the rst engine speed control to deliver so much in a package this compact. It can also deliver a big savings in production and eld support. Since the L Series Control System is 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 conguring the four auxiliary inputs at their factory.
Optional transient smoke limiter for turbocharged diesel engines Customer congurable auxiliary inputs available on board to match your specic application Optional mounting kits for Stanadyne DB-series or Delphi DP200 & DP210 fuel injection pumps provides integrated control solution Speed setpoint adjustment using Idle/Rated1/Rated2, Raise/Lower, and external analog settings Dual sets of speed dynamics can be set by engine speed, discrete input, or even an external signal
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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 111.3 mm (2.98 x 3.48 x 4.38 in.) Weight 425 g (15 oz) Connector 12-pin Deutsch connector (DT06-12SA-P012) Control Characteristics Speed Input Magnetic pickup or ignition coil and Range MPU input: 112 000 Hz, 1720 teeth, 1 Vrms min. IGN input: 1480 Hz, 120 cylinders with rated speed up to 4000 rpm Target speed: programmable Speed range: programmable Actuator Torque High-efciency 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%
Programming Port I/O
Programmable with Windows GUI software (9927-1222) and harness (8923-1061) 05 V throttle position indication Discrete out for fault indication 4 aux inputs, congurable functions 40 to +105 C (40 to +221 F) 40 to +125 C (40 to +257 F) EMC EN61000-6-2: Immunity for Industrial Environments EN61000-6-4: Emissions for Industrial Environments SAE J1113-21: Radiated Immunity (100 V/m) SAE J1113-11: Conducted Transient Immunity Pulse 5b, Suppressed Load Dump (45 V) US MIL-STD 810E, Method 507.3, Procedure III MS1-40G 11ms sawtooth Random: 0.3 G2/Hz, 102000 Hz (22.1 Grms) 3 h/axis Sine: 5 G 2.5 mm peak-to-peak, 52000 Hz, 3 h/axis, 90 min dwells, 1 octave/min SAE J1455, Paragraph 4.1.3.2 IP56 per EN60529 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
Environment Operating Temp Storage Temp
Humidity Shock Vibration
Thermal Shock Fluid Resistance Compliance CSA CE Other Technical Manual 26250
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
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ProAct Analog and Digital Plus

Electric Actuators with Integral Driver
03231F
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 buttery, eliminating linkage Multiple sizes to t broad range of applications Digital Plus: Single or redundant position command signals Congurable parameters to tailor to varied applications CAN communications Advanced Diagnostics
serrated tooth terminal shaft, and an optional rotation scale and indicator are available for visible travel detection. The actuators accept analog or PWM position command signals. In addition, the Digital Plus driver accepts CAN position command signals and can be congured for 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 eld programmable, allowing a single design to be used in many different applications. It must be congured and calibrated to the specic engine with a personal computer (PC) and a Woodward Watch Window Service Tool that communicates serially to the driver via RS-232 using Woodwards DDE ServLink protocol. Watch Window Standard can be ordered from Woodward on a CD-ROM (part number 1796-065), or it can be downloaded from the Woodward website (www.woodward.com). Data les for subsequent applications of the same engine model can be downloaded offengine. The ProAct Analog actuator/driver can be congured without a service tool. Refer to manual 26112 for more detailed information on the ProAct Digital Plus actuator, and to manual 26147 for more information on the ProAct Analog.
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 ange-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 0.625-36
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03231F
Maximum Current Transient 3.7 A Steady State 1A
GENERAL SPECIFICATIONS
Actuator Model Model I Part Number Analog Digital Plus Model II Analog Digital Plus Model III Digital Plus Weight 10.5 kg (24 lbs) 11 kg (25 lbs) 10.5 kg (24 lbs) 11 kg (25 lbs) 15 kg (32 lbs)
Minimum Work Output Transient 3.4 J 2.5 ft-lbs 7J 5 ft-lbs 14 J 10 ft-lbs 27 J 20 ft-lbs Steady State 1.7 J 1.25 ft-lbs 3.4 J 2.5 ft-lbs 7J 5 ft-lbs 14J 10 ft-lbs
Maximum Input Power Transient 67 W Continuous 19 W
251 W
65 W
14 A
4A
282 W
73 W
15.6 A
4A
Model IV
Digital Plus
24 kg (52 lbs)
370 W
100 W
20.6 A
5.6 A
END USER I/O DESCRIPTION

Analog
Power Input Command Input 1832 Vdc PWM: 732 V, 1503100 Hz Analog: 20180 mA, 420 mA, & 0.54.5 Vdc 0.5 Vdc and 4.5 Vdc corresponds to full CCW and CW, respectively Not Applicable Not Applicable Not Applicable Not Applicable
ENVIRONMENTAL SPECIFICATIONS
Digital Plus
1832 Vdc with out-of-range diagnostics PWM: 732 V, 100 to 3000 Hz Analog: 20180 mA or 420 mA CAN 4 mA and 20 mA corresponds to 0% and 100% actuator position Low Power standby mode Four CAN address combinations Normally ON turns OFF to indicate a detected fault 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. Operating Temperature Limits
Acceptable Range or Qualication 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 specication item.
Position Feedback Output Discrete Inputs Discrete Output RS-232 Serial Communications CAN 2.0B Serial Communications (optional)
Storage Temp Vibration Qualication Test Shock Qualication Test Ingress Protection Humidity Qualication Test Chemical Resistance
Sine: 3.2 mm peak-to-peak for 2-39.4 Hz, 10 G for 39.4-300 Hz. Random: 0.01 G2/Hz at 10 Hz, 0.10 at 100 Hz, 0.10 at 1000 Hz, 0.05 at 2000 Hz (12.79 Grms) 3 hours per axis. MS140G 11ms sawtooth. IP56 per EN 60529:1992. 60 C, 95% RH for ve 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.
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03231F
ProAct Analog Outline Drawing (Do not use for construction.)
ProAct Digital Plus Outline Drawing (Do not use for construction.)
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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
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 tting or a custom connector to be supplied by the customer. All inputs and outputs to the ProAct actuator are accessed beneath the end cover, which is fastened with 6 M4x10 mm screws. Input power is connected to size M4 screws, and the wires must be terminated with insulated spade or ring lugs. The I/O terminal blocks are screwless cage-clamp-style blocks that accept wires from 0.203.3 mm2 (2412 AWG) wire. Actuators with an MS-style connector mounted as an option on the end cover are also available. For OEMs, other factoryinstalled connectors may also be considered. Technical Manual Analog 26147 Digital Plus 26112
CERTIFICATIONS, AGENCY LISTINGS, AND REGULATORY COMPLIANCE

European Compliance for CE Mark EMC Directive: Declared to 89/336/EEC COUNCIL DIRECTIVE 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)
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ProAct ISC Integrated Speed Control

Electric Actuator with Integral Speed Control or Position Driver
03326
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 buttery, eliminating linkage Two sizes to t broad range of applications Congurable parameters to tailor to varied applications Advanced Diagnostics
DESCRIPTION
The ProAct ISC can be base or ange mounted on-engine, and will withstand high levels of vibration and temperature. The output shaft is a 0.625-36 serrated tooth shaft. Two levels of output torque are available. The ProAct ISC will also mount directly to Woodward integrated throttle bodies. The control accepts a speed input signal from a variable reluctance speed sensor, commonly called an MPU. The control may also be user-congured as a positioner 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 modier, analog input speed modier, analog raise and lower speed modier, 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 eld programmable, allowing a single design to be used in many different applications. It must be congured and calibrated to the specic engine with a personal computer (PC) and the ProAct ISC Service Tool that communicates serially to the control via RS-232 using Woodwards DDE ServLink protocol. The ProAct ISC Service Tool can be downloaded from the Woodward website (www.woodward.com/ic/software/). Refer to manual 26246 for more detailed information on the ProAct Integrated Speed Control.
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. Congured as a speed control, the ProAct ISC offers speed control with softwareselectable speed set points, dynamics, fuel limiting, and start/stop behavior. Congured as a positioner, the ProAct ISC offers position control with software selectable CW/CCW operation and eld calibration.
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03326
Maximum Current Transient 3.5 A 11 A Steady State 2A 3.5 A
GENERAL SPECIFICATIONS
Actuator Model Model I Model II Typical Part Number 8404-203 8404-204 Weight 10.5 kg 24 lbs 10.5 kg 24 lbs
Minimum Work Output Transient 2.5 J 22 in-lb 5J 44 in-lb Steady State 1.25 J 11 in-lb 2.5 J 22 in-lb
Maximum Input Power Transient 63 W 198 W Continuous 36 W 63 W
END USER I/O DESCRIPTION

Speed Control Conguration
Power Input Command Input Position Feedback Output Analog Inputs Analog Outputs Discrete Inputs Discrete Output RS-232 Serial Communications CAN 2.0B Serial Communications 1832 Vdc MPU (Magnetic Pickup) frequency input. 160 Vrms. 124 kHz Available, see Analog Output below. 4 mA and 20 mA corresponds to 0% and 100% actuator position. 420 mA, 05 Vdc, 3 Vdc 1 Available. 420 mA, 450 load 5 Available. Software selectable High / Low or Active Open / Closed 1 Available. Low side switch. 0.5 A Used for Service Tool Communications. Integral with main connector. Available for Boost Fuel Limit function
Positioner Conguration
1832 Vdc Analog: 420 mA, 05Vdc, 3 Vdc Available, see Analog Output below. 4 mA and 20 mA corresponds to 0% and 100% actuator position. See Command Input 1 Available. 420 mA, 450 load 5 Available. Software selectable High / Low or Active Open / Closed 1 Available. Low side switch. 0.5 A Used for Service Tool Communications. Integral with main connector. Hardware installed, future availability
ENVIRONMENTAL SPECIFICATIONS
Acceptable Range or Qualication Condition
Operating Temperature Limits Storage Temperature Vibration Qualication Test Thermal Shock Qualication Test Ingress Protection Humidity Qualication Test Chemical Resistance 40 to +85 C 40 to +125 C, unpowered RV2: US MIL -STD-202F, procedure 214A: 0.1 G2 / Hz, 102000 Hz, 3 hr /axis, 12.8 Grms Swept Sine 525 Hz, 1.6 mm, 25100 Hz 4.0 G Reference: SAE J1455, Paragraph 4.1.3.2 50 cycles from 40 oC to +125 oC. Unit unpowered. IP56 per EN 60529:1992. 60 C, 95% RH for ve 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.
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03326
ProAct Integrated Speed Control (Do not use for construction.)
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03326
ProAct Integrated Speed Control (Do not use for construction.)

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 26246 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.
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THROTTLE BODY PRODUCT OVERVIEW

L Series ITB Integrated Throttle Body The L Series ITB is a member of Woodwards Integrated Throttle Body family. Several throttle body size congurations (between 25 and 50 mm) are integrated with speed control or actuator options for use on gaseous fueled industrial engines between 5 and 100 kW (7 and 134 hp). Applications include automotive, power generation, refrigeration units, pumps, irrigation, mobile industrial, and gas trim valves. The L Series ITB integrated throttle body and speed control or actuator provides a building block approach to total engine management. This modular design consists of a die-cast aluminum throttle body plus a fully programmable integrated digital speed control and bi-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 ow shaping to assist in engine idle stability. The throttle body will provide equivalent maximum ow rates of standard buttery throttle bodies of the same diameter. The system contains a return spring to fully comply with DOT 571.124 specications. Determination of the proper size requires a knowledge of the absolute pressure drops across the valve, the expected temperature of the gaseous media owing, and the density of the gas. Cv (volume coefcients) are provided to determine the ow vs. angle. For initial testing, a valve body diameter similar to the one typically used on the application can be used. The Flo-Tech integrated actuator/throttle body requires no actuator or linkage. ProAct ITB Integrated Throttle Body The ProAct ITB integrated throttle body includes 107 mm, 120 mm, and 135 mm bore sizes, and is designed for use with engines in the 1-2 MW range. These large ITB units are made to couple directly to Woodwards ProAct actuators (an electromagnetic, 75-degree device), and therefore alleviate the problems associated with linkages on gas engines, such as non-linearity and wear. This direct combination of throttle and actuator results in excellent low-load stability and transient characteristics, and requires no hydraulics, pneumatics, or governor gear train.
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L Series ITB Integrated Throttle Body and Speed Control or Actuator

Overspeed/underspeed protection Remote speed setting Three speed select Error relay driver
03223
Integrated, bi-directional actuator or OEM-congurable speed control Eliminates external linkages Reduces total engine assembly costs Can be used in turbocharged applications with throttle pressure higher than ambient Optional PWM input positioner model with integral position feedback Sealed ballbearing throttle body design Full range of bore sizes available: 25, 30, 36, 43, 50 mm Tamperproof End-of-line programmable speed control
The L Series Actuator comes in two basic congurations with or without on-board nal drivers. The onboard driver version accepts a 732 Vdc, 1503100 Hz PWM position command signal. The version without drivers brings the actuator coil (4 @ 25 C, 14 mH @ 500 Hz) leads directly out to the Deutsch connector. The L Series Actuator also has an optional, integral 05 Vdc throttle position feedback signal.
DESCRIPTION APPLICATIONS
The L Series ITB is a member of Woodwards Integrated Throttle Body family. Several throttle body size congurations (between 25 and 50 mm) are integrated with speed control or actuator options for use on gaseous fueled industrial engines between 5 and 100 kW (7 and 134 hp). Applications include 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 congurations, as follows: Isochronous speed control Droop Auxiliary input Dual dynamics Adjustable ramp time Self-tuning gain 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 conguration. The L Series ITB speed control is compatible with Woodwards venturi-style mixer and other brands of gas mixers using suitable adapters (see L Series product specication 03225 for speed control details and operating parameters).
PAGE | 26
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)
03223
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.
Technical Manual 26135
Woodward 2005 All Rights Reserved.
PAGE | 27
Flo-Tech ITB
Integrated Throttle Body and Actuator
04140B
No linkage or couplings Cost-effective and highly efcient Extremely low maintenance product Small size for easy installation Conveniently integrated electronics Includes returnspring to fully comply with DOT 571.124 specs Versatile 12 or 24 Vdc operation
APPLICATIONS
The Flo-Tech ITB integrated throttle body and actuator is designed with ow shaping to assist in engine idle stability. The throttle body will provide equivalent maximum ow rates of standard buttery throttle bodies of the same diameter. The system contains a return spring to fully comply with DOT 571.124 specications. Determination of the proper size requires a knowledge of the absolute pressure drops across the valve, the expected temperature of the gaseous media owing, and the density of the gas. Cv (volume coefcients) are provided to determine the ow vs. angle. For initial testing a valve body diameter similar to the one typically used on the application can be used. The Flo-Tech ITB is designed for direct replacement of manual throttle bodies. It requires no actuator or linkage.
DESCRIPTION
The Flo-Tech family of electrically actuated throttles/valves controls ow. The ow is a function of throttle position and pressure drop. The throttle position is proportional to the position command signal. The Flo-Tech ITB can be made with 33, 48, 60, 68, and 75 mm bore sizes for various applications. Command input options come in PWM, 05 Vdc, 420 mA, and 0200 mA. Position feedback output signal will vary from 0.5 0.1 volts to 4.5 0.1 volts nominal at the min and max actuator position respectively. The PWM command input version will return to minimum actuator position with a command of greater than 95% duty cycle. The Flo-Tech actuator requires a power supply of 932 Vdc. The supply must be capable of supplying a sustained 25 watts at steady-state and 50 watts for transient state conditions for at least 0.25 second.
PAGE | 28
Flo-Tech ITB
04140B
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.
INSTALLATION
The Flo-Tech ITB integrated throttle body and actuator may be mounted in any position. Both mounting anges on the throttle body have four 10 mm through-holes in a square, 74 mm pattern. The base of the unit has an optional bolt pattern that can be used for mounting 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 8923-461) with seals and pins. Different connectors are available but not standard. Please contact the factory if you would like to use a different connector.
Cv for Standard Flo-Tech Units
DETERMINING PROPER VALVE SIZE

Proper valve size can be determined by using the following equation: Cv = Q * .00978 * (G * T / ((P1P2) * K)) ^ 0.5 Where: Q = Flow (PPH) G = Specic gravity of uid ( = 1.0 for air) T = Absolute temperature (460 + F) P1 = Inlet pressure (psia) P2 = Discharge pressure (psia) K = P2 if P1P2 is less than 10% of P1 = P1 if P1P2 is 25% or more of P1 = (P1+P2)/2 if P1P2 is in between 10 & 25%
P2 must be Greater than .53 * P1 (or ow becomes choked). Cv (ow coefcient) should be calculated for the minimum and maximum ows expected (at 50) on the application. Cv (Flow Coefcient) Angle
0 5 10 15 20 25 30 35 40 45 50 55 60 65 70
33mm
0.689 0.787 1.30 2.70 4.63 6.86 9.58 12.7 16.3 20.4 24.9 30.1 33.8 35.9 36.1
48mm
1.36 1.81 3.34 6.64 10.8 16.0 21.8 28.5 36.2 45.0 54.8 65.9 75.6 81.6 82.9
60mm
1.81 2.57 4.65 9.39 15.9 24.0 33.1 43.7 55.9 70.4 86.8 105 125 138 151
68mm
2.44 3.04 4.83 10.4 18.3 28.1 39.7 53.4 70.0 88.0 109 133 157 179 197
75mm
1.41 3.37 2.71 8.28 16.9 28.3 41.8 57.8 76.2 97.3 120 147 174 200 220
PAGE | 29
Flo-Tech ITB
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
Flo-Tech ITB
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 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 Using the max Cv number, and the chart below, Command select the Flo-Tech unit which most closely matches at 50 angle. Verify that the minimum required Cv is above the Flo-Tech units Cv ensuring the engine will reach idle when the Flo-Tech unit closes.
Technical Manual 04166

Input Command PWM 0-5 Vdc 4-20 mA 0-200 mA Input Range 10-90% 0.54.5 Vdc 519 mA 20180 mA Input Range 1090% 0.54.5 Vdc 519 mA 20180 mA Part No. 8235-132 8235-163 8235-142 8235-158 8235-167 8235-160 8235-157
Input Impedance 117.4 kA 152.7 kA 249 A 35.7 A Position Feedback Output 23 C 0.54.5 0.1 Vdc 0.54.5 0.1 Vdc 0.54.5 0.1 Vdc 0.54.5 0.1 Vdc
Other Commands PWM Frequency 5002000 Hz Amplitude 432 Vdc 10 bit resolution
OUTPUTS
Input Command PWM 0-5 Vdc 4-20 mA 0-200 mA
Position Feedback Outback 40 & 105 C 0.84.2 0.2 Vdc 0.84.2 0.2 Vdc 0.84.2 0.2 Vdc 0.84.2 0.2 Vdc
Nominal Actuator Range 070 070 070 070 Part No. 8235-143 8235-154 8235-151 8235-259 8235-152 8235-140
PART NUMBERS
Valve Size (mm) Input 33 33 48 48 48 60 60 PWM 4-20 mA PWM 4-20 mA 0-200 mA PWM 0-5 Vdc
Valve Size (mm) Input 60 68 68 68 68 75 4-20 mA PWM 0-5 Vdc 4-20 mA 0-200 mA PWM
PAGE | 31
ProAct ITB Integrated Actuator and Throttle

Body for Large Bores (105, 120, 135 mm)
03305B
No linkage or couplings Cost effective and highly efcient Low maintenance Requires no hydraulics, pneumatics, or governor gear train Long lasting, easy to install throttle option
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 specication.
DESCRIPTION
The PoAct Integrated Throttle Bodies (ProAct ITBs) are buttery valves electrically-actuated by ProAct Analog and ProAct Digital Plus actuators to control ow output. With bore sizes of 105 mm, 120 mm, and 135 mm, these ProAct ITBs are designed for use with engines in the 12 MW range. The ProAct actuators are electro-magnetic, 75 degree-of-travel devices, and therefore alleviate the problems associated with linkages on gas engines (such as setup, non-linearity, and wear). This direct combination of throttle and actuator results in excellent stability and transient characteristics, and requires no hydraulics, pneumatics, or governor gear train. Therefore, you end up with an efcient, long lasting, and easily-installed throttle option.
PAGE | 32

03305B
DETERMINING THE PROPER VALVE SIZE

The proper size valve can be determined using the equation below. The required Cv (ow coefcient) should be calculated for both the minimum and maximum ows expected on the application. This design allows for a nominal travel of 75 degrees of rotation. Using the graph and table below, select the closest valve that has a Cv equal to or greater than the calculated maximum ow value at approximately 80% opening (60 degrees) to ensure reasonable ow margin. Also, check that the particular valves minimum Cv listed below is less than the minimum calculated Cv for good low idle performance. For further assistance, consult the Woodward engineering department. Q.0.00976 . P1.Sg (T + 460).P1.Sg P1 P2
Cv vs Angle for ProAct ITBs
Cv :=
where: Cv = Flow Coefcient Q = Mass Flow (PPH [pounds/hour]) [1 pound = 0.45 kg] Sg = Specic Gravity of Gas (use 1.0 for air) T1 = Upstream Gas Temperature (F) [F = 1.8 * C +32] P1 = Inlet Pressure (psia) [1 psi = 6.895 kPa = 0.06895 bar] P2 = Downstream Pressure (psia) Note: P2 must be greater than 0.528 * P1 or ow becomes choked. If P2 is less than 0.528 * P1, then use P2= 0.528 * P1.
Cv (Flow Coefcient)
Plate Angle
0 5 15 25 35 45 55 65 75
105 mm
1.04 7.53 26.37 58.74 97.05 156.83 244.65 369.57 509.52
120 mm
1.09 8.68 30.42 68.96 127.28 215.44 350.02 563.30 810.50
135 mm
1.10 11.51 40.67 93.33 172.75 292.46 471.51 782.29 1214.00
Note: These ow coefcients were determined using the test setup described in ANSI/ISA-S75.021996 Control Valve Capacity Test Procedure.
PAGE | 33

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

03305B
ProAct ITB 135 with ProAct Digital Plus Model III (Do not use for construction.)
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 Qualication Woodward RV2 (0.1 G2/Hz Random, Test Spec 102000 Hz, 12.8 Grms 3 hours per axis) Shock Qualication 40 G, 11 ms sawtooth pulse Test Spec Weight See table under mounting section of 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 04166 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 Certied 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.
PAGE | 35
3800 NORTH WILSON AVENUE, LOVELAND, CO 80538 PH: +1 (970) 962-7517 FAX: +1 (970) 962-7515 WWW.WOODWARD.COM/SMARTFIRE WWW.WOODWARD.COM
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Woodward 2005 All Rights Reserved.

DETERMINING PROPER VALVE SIZE

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

Technical Manual 04166

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