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RAPTOR™
Gas Regulation and Metering
Valve/Actuator System for
Caterpillar
Manual 26090B
WARNING
Read this entire manual and all other publications pertaining to the work to
be performed before installing, operating, or servicing this equipment.
Practice all plant and safety instructions and precautions. Failure to follow
instructions can cause personal injury and/or property damage.
The engine, turbine, or other type of prime mover should be equipped with
an overspeed (overtemperature, or overpressure, where applicable)
shutdown device(s), that operates totally independently of the prime mover
control device(s) to protect against runaway or damage to the engine,
turbine, or other type of prime mover with possible personal injury or loss
of life should the mechanical-hydraulic governor(s) or electric control(s),
the actuator(s), fuel control(s), the driving mechanism(s), the linkage(s), or
the controlled device(s) fail.
CAUTION
To prevent damage to a control system that uses an alternator or battery-
charging device, make sure the charging device is turned off before
disconnecting the battery from the system.
IMPORTANT DEFINITIONS
WARNING—indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
NOTE—provides other helpful information that does not fall under the
warning or caution categories.
Woodward Governor Company reserves the right to update any portion of this publication at any time. Information
provided by Woodward Governor Company is believed to be correct and reliable. However, no responsibility is
assumed by Woodward Governor Company unless otherwise expressly undertaken.
© 2001 by Woodward Governor Company
All Rights Reserved
Manual 26090 RAPTOR Valve/Actuator System
Contents
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RAPTOR Valve/Actuator System Manual 26090
Figure 3-1a. RAPTOR Valve Outline Drawing (1000 and 2000 mm) .....................6
Figure 3-1b. RAPTOR Valve Outline Drawing (1000 and 2000 mm) .....................7
Figure 3-2. RAPTOR Valve Wiring Diagram ..........................................................8
Figure 3-3. Flashing Code Example .....................................................................12
Figure 5-1. RAPTOR Valve Sizing Diagram .........................................................18
Figure 7-1. Installing the Sensor Module ..............................................................28
Figure 7-2. Connecting the Sensor Module Ribbon Cable ...................................29
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Manual 26090 RAPTOR Valve/Actuator System
Chapter 1.
General Information
Introduction
The RAPTOR™ product is an integrated, digitally compensated control valve
and actuator system for regulating and metering the flow of gaseous fuels. The
device is designed to accept a fuel rate demand signal. It also incorporates
feedback sensors which monitor fuel pressure and temperature, and valve
pressure differential. Based on the signal inputs, the device modulates the valve
opening to produce a physical fuel mass flow which closely matches the flow
demand level.
NOTE
Throughout the remainder of the manual, the RAPTOR valve and
actuator system will be referred to simply as the RAPTOR valve.
The RAPTOR valve has one service port for program upgrades by qualified
service personnel.
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RAPTOR Valve/Actuator System Manual 26090
General Installation and Operation Notes and
Warnings
The RAPTOR valve is suitable for use in Class I, Division 2, Group C, and D per
CSA for Canada and U.S. or non-hazardous location only.
The RAPTOR valve wiring must be in accordance with the Class I, Division 2
wiring methods and in accordance with the authority having jurisdiction.
Wiring for the RAPTOR valve power input must be suitable for at least 85 °C.
WARNING
Explosion Hazard—Do not remove covers or connect/disconnect
electrical connectors unless power has been switched off or the area
is known to be non-hazardous.
AVERTISSEMENT
Risque d'explosion—Ne pas enlever les couvercles, ni raccorder /
débrancher les prises électriques, sans vous en assurez auparavant
que le système a bien été mis hors tension; ou que vous vous situez
bien dans une zone non explosive.
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Manual 26090 RAPTOR Valve/Actuator System
Chapter 2.
Electrostatic Discharge Awareness
4. Do not remove the printed circuit board (PCB) from the control cabinet
unless absolutely necessary. If you must remove the PCB from the control
cabinet, follow these precautions:
• When replacing a PCB, keep the new PCB in the plastic antistatic
protective bag it comes in until you are ready to install it. Immediately
after removing the old PCB from the control cabinet, place it in the
antistatic protective bag.
CAUTION
To prevent damage to electronic components caused by improper
handling, read and observe the precautions in Woodward manual
82715, Guide for Handling and Protection of Electronic Controls,
Printed Circuit Boards, and Modules.
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Manual 26090 RAPTOR Valve/Actuator System
Chapter 3.
Installation
Introduction
WARNING
The RAPTOR™ valve weighs 43 kg (94 lbs). In order to prevent injury,
some form of lifting assistance (a lifting strap is recommended)
should be used when handling the RAPTOR valve.
Be careful when unpacking the RAPTOR valve. Check the assembly for signs of
damage, such as bent or dented covers, scratches, and loose or broken parts.
Notify the shipper and Woodward if damage is found.
Mounting
The RAPTOR valve is designed to operate within a temperature range of 0 to 85
°C (32 to 185 °F) with a gaseous fuel flow temperature of 0 to 60 °C (32 to 140
°F).
The RAPTOR valve should be mounted with the electronic enclosure facing up.
It must be mounted onto a flat plate with 0.500-13 size bolts. Consideration must
be given to the strength of the mounting plate, in order to support the 43 kg (94
lbs) weight of the RAPTOR valve.
The inlet piping of the RAPTOR valve must be in accordance with ANSI/ISA-
S75.02 as required for flow metering accuracy. There are two outlet piping
solutions possible:
• Straight flow
• Tee flow
The straight flow solution is used mainly for in-line engines or engines with only
one cylinder bank.
The tee flow solution is mainly used for V engines or engines with two cylinder
banks, two mixers, and two turbos.
NOTE
Close the unused ports with appropriate blocking flanges and
gaskets (not delivered with the RAPTOR valve). Plug unused
pressure ports (P2 inlet—see outline drawing) with 0.125 NPT pipe
plug(s) if applicable.
The outlet piping solution for each RAPTOR valve is indicated on the
device nameplate.
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WARNING
Leak check all gaseous fuel connections. Leaking gaseous fuel can
cause explosion hazards, property damage, or loss of life.
Figure 3-1a. RAPTOR Valve Outline Drawing (1000 and 2000 mm)
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Manual 26090 RAPTOR Valve/Actuator System
Figure 3-1b. RAPTOR Valve Outline Drawing (1000 and 2000 mm)
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Electrical Connections
The RAPTOR valve is connected to the control system (ECM) by the main
connector. The engine harness mating connector is an Amphenol GTC06CF20-
29S(025)188.
To Previous CAN
Device
}
RAPTOR
C CAN HI IN
F CAN LO IN
N CAN HF GND
D CAN HI OUT
E CAN LO OUT
R
Jumper for CAN Termination
P
}
Resistor
To Next CAN
J SPARE
Device
H SPARE
A CAN ID1
B CAN ID2
G SPARE
S
T
PWM IN +
PWM IN - } SeeBelow
Options
M Key Switch
Battery
K Battery +
L Battery -
ECM ECM
S PWM IN + S PWM IN +
T PWM IN - T PWM IN -
return to
Battery -
L Battery -
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Manual 26090 RAPTOR Valve/Actuator System
WARNING
Explosion Hazard—Do not remove covers or connect/disconnect
electrical connectors unless power has been switched off or the area
is known to be non-hazardous.
AVERTISSEMENT
Risque d'explosion—Ne pas enlever les couvercles, ni raccorder /
débrancher les prises électriques, sans vous en assurez auparavant
que le système a bien été mis hors tension; ou que vous vous situez
bien dans une zone non explosive.
Supply Voltage
K = Supply voltage (+)
L = Supply voltage (–)
Key Switch
M = Key switch
The key switch is used to cycle power to the RAPTOR valve. A high signal
(connected to supply [+]) will turn the valve on, and a low signal (connected to
supply (–) or open connection) will turn it off. This signal provides a convenient
way to shut down the RAPTOR valve, so that a high-power (6 A) relay is not
needed at the supply voltage input. When the key switch input goes low, the
valve will switch off the internal power after the software has gone through a
shutdown procedure.
PWM Input
S = PWM input (+)
T = PWM input (–)
The PWM input is used as the secondary mass flow demand input. The scaling
used on this secondary flow demand is received from the ECM via CAN and
stored in the RAPTOR valve. It will switch to this input automatically if the
CAN link, or primary flow demand input, is lost.
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As shown in Figure 3-2, there are two options for connecting the PWM input to
the ECM. In the single-wire configuration, the RAPTOR PWM (–) input should
be connected to the RAPTOR Battery (–) pin.
If the RAPTOR valve has detected a shutdown failure (closing the valve if
possible), the pull-up resistance on the PWM input is opened. An ECM which
has open-circuit detection capability on its PWM driver can then detect that the
RAPTOR valve has shutdown, even if the CAN link diagnostics have been lost.
CAN ID Inputs
A = CAN ID 1
B = CAN ID 2
The CAN ID inputs are used to select which CAN identifiers will be used on the
CAN bus. With no programming tools, the customer can select from the four
pre-programmed CAN IDs through a hard-wired code in the engine harness. This
is especially important where more than one RAPTOR valve is used on an
engine. If one RAPTOR valve is replaced with another, the new valve will read
the correct ID number from the engine harness connector. See the table below
for the code definition.
CAN Termination
R = Termination resistor
P = Termination resistor
The internal termination resistor is used to terminate the CAN bus. According to
the CAN specification, every CAN bus must be terminated at both ends of the
bus. If a RAPTOR valve is connected to the far end of the bus, this termination
resistor can be used. If termination is needed, connect a link between pin P and
pin R. This link should be as short as possible. If no termination resistor is
needed, leave pins R and P unconnected.
WARNING
If the internal termination is used, other devices on the CAN bus may
not operate properly when the RAPTOR valve is disconnected from
the bus. An external termination resistor should be used if there are
other devices on the CAN bus that must not lose communication
when the RAPTOR valve is disconnected.
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Manual 26090 RAPTOR Valve/Actuator System
CAN 1 (in)
C = CAN high in
F = CAN low in
Pins C and F are the CAN communication wires. Make sure that the correct
cable is used for connection to the CAN terminals (SAE J1939/11).
CAN 2 (out)
D = CAN high out
E = CAN low out
The CAN output pins are internally connected to the CAN input pins. They are
provided for linking more then one RAPTOR valve to the CAN bus without the
need for junction boxes or doubled terminations to connector pins. For example,
the CAN bus from the control may be connected to the input pins, and the output
pins are connected to the second RAPTOR valve input pins.
WARNING
If a second device is connected to the CAN output pins, this device
will lose communication if the RAPTOR valve is disconnected.
CAN HF Ground
The CAN HF (High Frequency) ground can by used to terminate the shield of
the CAN wiring. Internally, this pin is connected to the RAPTOR case through a
capacitor.
Diagnostics
The RAPTOR valve, being a “smart valve”, has advanced diagnostics. There are
two ways of communicating the diagnostic codes:
• CAN link
• Diagnostic LED (visible on the cover)
WARNING
The RAPTOR valve may not return to minimum fuel for all faults. The
engine, turbine, or other type of prime mover should be equipped
with an over speed, misfire, detonation detection shutdown
device(s), that operate totally independently of the prime mover
control device(s) to protect against runaway or damage to the engine,
turbine, or other type of prime mover with possible personal injury or
loss of life should the RAPTOR system fail.
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RAPTOR Valve/Actuator System Manual 26090
The Raptor diagnostic codes are displayed on the diagnostic LED by flash codes:
• Flashing Green: Normal run
• Orange Code: Alarm—see troubleshooting guide for code descriptions
• Red Code: Shutdown—see troubleshooting guide for code descriptions
Code: 4 2
Figure 3-3. Flashing Code Example
The flash code starts with the tens digit of the error code. After a delay, the ones
digit is flashed. A zero in the ones digit causes ten blinks. The error code in the
above example is 42.
For error code descriptions and appropriate action see the troubleshooting
chapter.
Service Port
The service port (Figure 3-1a) provides an RS-232 connection for
troubleshooting purposes. It is intended for use by Woodward certified
personnel. In case this cover is removed, torque the screws to 2.7 Nm (24 lb-in).
NOTE
Proper torque is very important to ensure that the unit is sealed
properly.
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Manual 26090 RAPTOR Valve/Actuator System
Chapter 4.
Description of Operation
WARNING
Due to typical noise levels in engine environments, hearing
protection should be worn when working on or around the
RAPTOR™ valve.
Power On Procedure
The RAPTOR valve is typically continuously connected to the supply voltage.
When the key switch input is connected to a high signal (supply [+]), the
RAPTOR valve will switch its internal supply voltage on. The processor then
performs a diagnostic check. If there are no problems detected, the valve will
read the CAN ID input pins and begin sending diagnostic information on the
CAN link. The RAPTOR valve will annunciate the CAN ID code by displaying
one, two, three, or four red flashes on the diagnostic LED.
The actuator is powered and positions the valve at its minimum position. If there
is a problem detected with positioning the valve, the valve will be closed against
the minimum mechanical stop, if possible. Next, the RAPTOR valve checks for
flow parameters (Specific Gravity, K factor, and Max PWM values) in non-
volatile memory. If these values are not available, the valve will remain at
minimum position and will send diagnostic messages until these values are
received by CAN communication.
If the Specific Gravity, K and Max PWM values are available, the RAPTOR
valve will look for a Qgn (mass flow demand signal) on the CAN bus. If this
signal is not received, it will switch to the PWM secondary (backup) mass flow
demand signal. If neither signal is available the RAPTOR valve will set the flow
demand to zero internally.
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If a valid flow demand is received, the RAPTOR valve will calculate the area
needed by the valve to provide the correct flow. This area is calculated using the
delta pressure, DP (inlet to outlet pressure differential), the absolute inlet Fuel
Gas Pressure (FGP), the Fuel Gas Temperature (FGT), the Qgn (Demand signal),
the Gas properties Sg and K, and the calibration information stored in the valve.
The actuator then positions the valve to achieve the calculated area.
NOTE
If the flow demand is zero for longer than 10 second, the RAPTOR
valve will disable the actuator coil (no power to the coil) so that the
valve will consume less power.
Specifications
Electrical Characteristics
• Input voltage range: 18–32 Vdc
• Normal input current range (steady-state, maximum): 0.2 to 3 A
• Maximum continuous input current: 4 A
• Maximum transient input current: 6 A
• PWM Frequency: 175 to 185 Hz
Mechanical Characteristics
Valve Geometric Area
• RAPTOR 1000: 1070 mm² (1.659 in²)
• RAPTOR 2000: 2018 mm² (3.128 in²)
• See section on valve sizing for detailed information.
Weight
• RAPTOR 1000 and 2000: 43 kg (94 lbs)
Mounting
• See installation drawings
Fuel connections
• Filter requirements: less than 1.0 µm
• See installation drawings
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Manual 26090 RAPTOR Valve/Actuator System
Environmental
Fuel Type
The RAPTOR fuel metering valve is designed to handle pipeline, landfill, digester
and other gases consisting of gaseous hydrocarbons, carbon monoxide, carbon
dioxide, hydrogen, oxygen, nitrogen and other constituents with the following
characteristics:
1. Sulfur compounds including Hydrogen Sulfide less than 0.780e-3 ppm
2. Chlorine compounds (typically chlorofluorocarbons) less than 0.260e-3 ppm
3. Fluorine compounds (typically chlorofluorocarbons) less than 0.140e-3 ppm
4. Silicon less than 0.008e-3 ppm
5. Ammonia less than 0.039e-3 ppm
6. Water less than 80% relative
humidity
7. Oil or Liquid Hydrocarbons in mist form less than 0.016e-3 ppm
8. Particulates, including silicon less than 0.011e-3 ppm
and sized less than 1.0
µm
Pressure
• Operating inlet fuel pressure range: 3.5 to 35 kPa (0.5 to 5.1 psig) inlet
• Maximum inlet operating pressure (such as during crank): 56 kPa (8.1 psig)
• Proof pressure 82 kPa (11.9 psig)
• Burst pressure 275 kPa (39.9 psig)
Temperature
• Ambient 0–85 °C (32–185 °F)
• Fuel Temperature 0–60 °C (32–140 °F)
Flow Characteristics
Accuracy
The RAPTOR control valve meters fuel accurately such that the engine starts
consistently and accelerates smoothly to idle speed. The required fuel delivery
between cranking and idle operation is within ±10% of the mass flow demand.
Throughout the load range, from idle to 100% load, the RAPTOR regulates the
fuel delivery accurately relative to the fuel flow demand in order to reduce
combustion emissions and protect the engine against detonation. The accuracy is
within ±5% of the mass flow demand from idle to 50% load and within ±2% of the
mass flow demand above 50% load.
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RAPTOR Valve/Actuator System Manual 26090
Regulatory Compliance
European Compliance for CE Mark
EMC Directive: Certified to 89/336/EEC COUNCIL DIRECTIVE of 03
May 1989 on the approximation of the laws of the
Member States relating to electromagnetic
compatibility.
This product is certified as a component for use in other equipment. The final
combination is subject to acceptance by CSA International or local inspection.
Other Compliance
Meets or exceeds Woodward’s Automotive EMC Environment Test Requirements
16 Woodward
Manual 26090 RAPTOR Valve/Actuator System
Chapter 5.
Valve Sizing
The RAPTOR™ valve can be equipped with one of two trim sizes, 1000 or 2000
mm². In order to determine what trim size is needed for a particular application,
the following Valve Sizing Diagram (Figure 5-1) has been provided. In addition
to the available trim sizes, the TecJet™ gas metering valve (product
specification 36116) sizing limits have also been added to this diagram for
reference.
The RAPTOR Valve Sizing Diagram outlines the maximum flow capabilities for
a given trim size across a variety of gases and valve pressure drops. To use the
diagram, the maximum flow rate for a given application must be determined in
either a metric mass flow rate (kg/hr) or an English volume flow rate (scfm).
This value is found on the X-axis of the diagram. Choose the appropriate gas
type: natural gas, air, or specialty gas. Then choose the appropriate flow rate
units. The next step will be to find the valve pressure drop at maximum flow on
the Y-axis of the diagram. Metric (kPa) and English (psid) units are provided.
Take the flow rate value and the pressure drop value, and determine where they
cross on the diagram. This is the maximum flow rate operating point. To choose
a trim size, simply pick the closest curve to the right of the intersection point and
read what trim size the curve represents. Both the 80% and 100% flow area
curves are given in the diagram. This is to aid in determining how much flow
margin above the required maximum flow rate is available for a given trim size.
If 20% margin is required, use only the 80% flow area curve for sizing, if 0%
margin is required, use only the 100% curve, and so on. Interpolation can be
done to find intermediate margins if necessary.
As an example, let’s say the maximum flow requirement is 400 kg/hr natural gas
with a valve pressure drop of 9 kPa. Using the diagram, the closest curve to the
right of this intersection point is the RAPTOR 1000, 100% flow area.
Furthermore, a closer look shows a flow margin of approximately 15%. In this
case, the RAPTOR 1000 trim size would be appropriate.
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RAPTOR VALVE SIZING DIAGRAM
18
100
90
80
70
60
8
50 7
40 6
5
30
4
20 3
10
∆P (psid)
9
8
7 1
∆P (kPa)
1 TecJet50 80 % Flow Area
6
RAPTOR Valve/Actuator System
100 200 300 400 500 600 700 800 900 1000 2000 10,000
Air or Specialty Gas (scfm) SG=1.0, K=1.4
100 200 300 400 500 600 700 800 900 1000 2000 10,000
Manual 26090
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Manual 26090 RAPTOR Valve/Actuator System
Chapter 6.
Troubleshooting
WARNING
The actions described may not be appropriate for all situations. The
operator should verify that any actions taken while troubleshooting
will not take equipment outside of specification, and will not damage
property or result in dangerous situations. Also check with the local
safety authority.
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RAPTOR Valve/Actuator System Manual 26090
Table 6-1. Troubleshooting Guide: Normal Run Mode
Normal Run Mode:
Flash Description Color Internal RAPTOR Possible Source Possible Action
Code Error Error Code
Log
Code
Steady The RAPTOR Green N/A All codes false None Check the engine
Flashing did not detect trouble shooting guide
any diagnostics for more information.
or events. The RAPTOR has not
detected any events
or diagnostics.
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Manual 26090 RAPTOR Valve/Actuator System
Chapter 7.
Maintenance
CAUTION
Electronic devices contain static-sensitive parts. Observe the
following precautions to prevent damage to these parts.
1. Discharge body static before handling the device (with power to
the device turned off, contact a grounded surface and maintain
contact while handling the device).
2. Avoid all plastic, vinyl, and Styrofoam (except antistatic versions)
around printed circuit boards.
3. Do not touch the components or conductors on a printed circuit
board with your hands or with conductive devices.
1. Turn off power to the RAPTOR and disconnect the main cable.
2. Remove the lid by removing 18 #8 hex-headed screws around the edge and
four #8 hex-headed screws near the main connector.
3. Locate the 16-wire ribbon cable (53a) that connects the sensor module to the
main board. Remove the cable from the main board as follows: Remove the
two #6 phillips head screws (57) on the clamp at the main board end of the
sensor cable. Set aside the clamp and foam strip (55 and 56). Pull the end of
the cable directly up and off the connector pins.
4. Remove the four socket head cap screws holding the sensor module (53) to
the main housing.
5. Pull the sensor module straight up and out of the housing. Slightly twisting
the module while pulling may be required.
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6. Install new O-rings (50, 51, and 52) on new sensor module using petroleum
grease to hold in place. The two small O-rings (51) are placed in the two
small counterbores (pressure ports). The single medium sized O-ring (50) is
slid over the temperature sensor probe all the way to the groove (make sure
to lubricate this O-ring to ease installation of the sensor module into the
housing). The large O-ring (52) is placed in the “race-track,” held in place
with grease.
7. Lubricate the temperature sensor counterbore (24a) in the housing with
petroleum grease. Insert new sensor module into housing while ensuring that
the o-rings on the bottom remain properly seated.
8. Install the four socket head cap screws (54) holding the sensor module to the
housing, torque to 8.22 to 8.5 Nxm (73 to 75 lb-in).
9. Connect the ribbon cable (53a) to the main board by aligning the end of the
cable with the connector pins and pushing straight down. Make sure that
both rows of connector pins are engaged. Center the foam strip (55) in the
clamp (56), and install the clamp with the two #6 phillips headed screws
(57). Torque to 1.6 to 1.7 Nxm (14 to 15 lb-in).
10. Make sure that the O-rings, one around the connector and one around the
outside of the lid, are properly seated in their grooves.
11. Fasten the lid using the 18 #8 hex-headed screws around the edge and four
#8 hex-head screws around the connector. Torque both sets of screws to 3.1
to 3.2 Nxm (27 to 28 lb-in).
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Manual 26090 RAPTOR Valve/Actuator System
Chapter 8.
Software Upgrade
The RAPTOR™ software can be updated by loading a new program through the
service port on the RAPTOR valve.
WARNING
Explosion Hazard—Do not remove covers or connect/disconnect
electrical connectors unless power has been switched off or the area
is known to be non-hazardous.
AVERTISSEMENT
Risque d'explosion—Ne pas enlever les couvercles, ni raccorder /
débrancher les prises électriques, sans vous en assurez auparavant
que le système a bien été mis hors tension; ou que vous vous situez
bien dans une zone non explosive.
Connect a serial cable between a computer and the RAPTOR assembly. The
RAPTOR assembly has a male 9-pin Sub-D connector, and connects to the 9-pin
COM port of a PC using a null modem cable (pins 2 and 3 cross over within the
cable). Only pins 2, 3, and 5 are used (it is not a problem if the other pins are
connected).
Load the ServLink and Watch Window software on the computer. Follow the
procedure supplied with the software.
Activate the ServLink server and set the communication parameter. See server
online documentation.
Open a new net and wait until the net is displayed on the server screen. Start
Watch Window. Right click on the Raptor TAB. A menu will pop up. Select load
application select the file and click “ok”. Wait until Watch Window indicates
that the application has been successfully changed.
Read the documentation that is provided with the new “RAPTOR.SCP” file this
may contain additional information about changes to be made to RAPTOR valve
to work with the new software.
CAUTION
Ensure that the serial cable is removed and the port cover is replaced
after the software upgrade is complete. Electromagnetic robustness
to high strength fields is not ensured with a cable connected.
An unsafe condition could occur with improper use of these software
tools. Only trained personnel should have access to these tools.
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Manual 26090 RAPTOR Valve/Actuator System
Chapter 9.
Applicable Documents
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34 Woodward
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Woodward/Industrial Controls
PO Box 1519, Fort Collins CO 80522-1519, USA
1000 East Drake Road, Fort Collins CO 80525, USA
Phone +1 (970) 482-5811 • Fax +1 (970) 498-3058
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FM 57982
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6 March 2001
01/8/F