Product Manual 26246

(Revision T, 7/2016)
Original Instructions

ProAct™ ISC Integrated Speed Control

Actuator Models I through IV

Installation and Operation Manual

 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.
General
Precautions Failure to follow instructions can cause personal injury and/or property damage.

This publication may have been revised or updated since this copy was produced.
To verify that you have the latest revision, check manual 26455, Customer
Publication Cross Reference and Revision Status & Distribution Restrictions, on
Revisions the publications page of the Woodward website:
www.woodward.com/publications

The latest version of most publications is available on the publications page. If

your publication is not there, please contact your customer service representative
to get the latest copy.

Any unauthorized modifications to or use of this equipment outside its specified

mechanical, electrical, or other operating limits may cause personal injury and/or
property damage, including damage to the equipment. Any such unauthorized
Proper Use modifications: (i) constitute "misuse" and/or "negligence" within the meaning of
the product warranty thereby excluding warranty coverage for any resulting
damage, and (ii) invalidate product certifications or listings.

If the cover of this publication states "Translation of the Original Instructions"

please note:
The original source of this publication may have been updated since this
Translated translation was made. Be sure to check manual 26455, Customer Publication
Publications Cross Reference and Revision Status & Distribution Restrictions, to verify whether
this translation is up to date. Out-of-date translations are marked with . Always
compare with the original for technical specifications and for proper and safe
installation and operation procedures.

Revisions—Changes in this publication since the last revision are indicated by a black line
alongside the text.

Woodward reserves the right to update any portion of this publication at any time. Information provided by Woodward is
believed to be correct and reliable. However, no responsibility is assumed by Woodward unless otherwise expressly
undertaken.
Manual 26246
Copyright © Woodward 2003—2016
All Rights Reserved
Manual 26246 ProAct ISC

Contents

WARNINGS AND NOTICES .......................................................................... IV

ELECTROSTATIC DISCHARGE AWARENESS ................................................. V
REGULATORY COMPLIANCE ...................................................................... VI
CHAPTER 1. GENERAL INFORMATION .......................................................... 1
Purpose and Scope ................................................................................................ 1
Intended Applications ............................................................................................. 1
Introduction ............................................................................................................. 1
Basic Control Options ............................................................................................. 2
Service Tool Software ............................................................................................ 2
References ............................................................................................................. 2
CHAPTER 2. INSTALLATION ........................................................................ 7
Introduction ............................................................................................................. 7
Unpacking and Handling ........................................................................................ 7
Mounting Location .................................................................................................. 8
Electrical Connections ..........................................................................................11
CHAPTER 3. DESCRIPTION OF OPERATION ................................................ 20
General .................................................................................................................20
System Operation .................................................................................................21
Controller Features Description ............................................................................21
Actuator Function .................................................................................................21
Speed Control Functions ......................................................................................22
Speed Control Dynamics ......................................................................................27
Start Fuel Limiting .................................................................................................29
Runtime Fuel Limiting ...........................................................................................30
Analog Output .......................................................................................................32
Discrete Output .....................................................................................................33
Temperature Sensing ...........................................................................................33
Current Limiting based on Temperature ...............................................................33
ProAct ISC Alarms and Shutdowns ......................................................................34
CHAPTER 4. SERVICE TOOL ..................................................................... 37
Description ............................................................................................................37
Getting Started .....................................................................................................38
Monitoring the Driver ............................................................................................39
CHAPTER 5. CONFIGURATION ................................................................... 46
Introduction ...........................................................................................................46
Overview ...............................................................................................................46
Configuration Parameters.....................................................................................47
CHAPTER 6. SETUP, CALIBRATION, AND TUNING ....................................... 71
Introduction ...........................................................................................................71
Control Setup ........................................................................................................71
Position Calibration and Verification .....................................................................72
Tuning the Speed Control Dynamics ....................................................................75
CHAPTER 7. SOFTWARE UPGRADE PROCEDURE ....................................... 78
Introduction ...........................................................................................................78
Install Watch Window Professional ......................................................................78
Install ProAct ISC Service Tool ............................................................................78

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Contents

CHAPTER 8. CAN DETAILS ...................................................................... 79

Overview ...............................................................................................................79
CAN Bit Timing .....................................................................................................79
Source Address/Harness Code Strategy .............................................................79
Configuration Strategy ..........................................................................................79
CAN Messages .....................................................................................................79
Diagnostics from ProAct ISC ................................................................................81
Diagnostics/Events ...............................................................................................82
Event Codes .........................................................................................................83
Transmission Rate ................................................................................................83
Arbitration .............................................................................................................84
CHAPTER 9. TROUBLESHOOTING .............................................................. 85
Introduction ...........................................................................................................85
Troubleshooting the ProAct ISC ...........................................................................85
Troubleshooting Diagnostic Flags ........................................................................87
CHAPTER 10. PRODUCT SUPPORT AND SERVICE OPTIONS ......................... 92
Product Support Options ......................................................................................92
Product Service Options .......................................................................................92
Returning Equipment for Repair ...........................................................................93
Replacement Parts ...............................................................................................93
Engineering Services ............................................................................................94
Contacting Woodward’s Support Organization ....................................................94
Technical Assistance ............................................................................................95
APPENDIX A. PROACT ISC CONTROL MODES ........................................... 96
Introduction ...........................................................................................................96
State Descriptions.................................................................................................96
State Transitions ...................................................................................................97
APPENDIX B. PROACT GENERAL SPECIFICATIONS .................................. 105
REVISION HISTORY ................................................................................ 107
DECLARATIONS ..................................................................................... 108

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Illustrations and Tables

Figure 1-1. Outline Drawing, Models I and II .......................................................... 3

Figure 1-2. Outline Drawing, Model III .................................................................... 4
Figure 1-3. Outline Drawing, Model IV ................................................................... 5
Figure 1-4. Control Wiring Diagram ........................................................................ 6
Figure 2-1. Fuel Stops ..........................................................................................10
Figure 2-2. Correct and Incorrect Wiring to Power Supply ...................................13
Figure 3-1. Remote Speed Setpoint Operation ....................................................25
Figure 3-2. Speed Droop ......................................................................................27
Figure 3-3. Control Gain as a Function of Speed Error ........................................28
Figure 3-4. Start Fuel Limit ...................................................................................29
Figure 3-5. Dual Start Fuel Limit with Ramp ........................................................30
Figure 3-6. Runtime Fuel Limiting Curve ..............................................................31
Figure 3-7. Boost (External) Fuel Limit .................................................................32
Figure 3-8. Temperature vs. Current Limit ...........................................................33
Figure 4-1. Communication Harness Connections ..............................................37
Figure 4-2. Service Tool Screen Example............................................................38
Figure 4-3a. Service Tool—Overview Tab (Speed Control) .................................41
Figure 4-3b. Service Tool—Overview Tab (Position Control) ..............................41
Figure 4-4. Service Tool—Alarms Tab .................................................................43
Figure 4-5. Service Tool—Shutdowns Tab ..........................................................44
Figure 4-6. Service Tool—Internal Shutdowns Tab .............................................44
Figure 4-7. Service Tool—Identification Tab ........................................................45
Figure 8-1. Typical Arbitration Field Example ......................................................84
Figure A-1. Start Fuel State When Two Start Fuels are Configured ....................98
Figure A-2. Running State When Configured for Rated Speed Setpoint .............99
Figure A-3. Running State When Configured for Idle / Rated Speed Setpoint ....99
Figure A-4. Running State When Configured for Runtime Select Rated 1 / 2
Speed Setpoint ..............................................................................100
Figure A-5. Running State When Configured for Start-up Select Rated 1 / 2
Speed Setpoint ..............................................................................100
Figure A-6. Start Fuel Diagram ..........................................................................103
Figure A-7. Speed Setpoint Diagram .................................................................104
Figure B-1. Transfer Function ............................................................................105

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Warnings and Notices

Important Definitions
This is the safety alert symbol. It is used to alert you to potential
personal injury hazards. Obey all safety messages that follow this
symbol to avoid possible injury or death.
 DANGER—Indicates a hazardous situation which, if not avoided, will result
in death or serious injury.
 WARNING—Indicates a hazardous situation which, if not avoided, could
result in death or serious injury.
 CAUTION—Indicates a hazardous situation which, if not avoided, could
result in minor or moderate injury.
 NOTICE—Indicates a hazard that could result in property damage only
(including damage to the control).
 IMPORTANT—Designates an operating tip or maintenance suggestion.

The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
Overspeed / loss of life, or property damage.
Overtemperature / The overspeed shutdown device must be totally independent of the
Overpressure prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.

The products described in this publication may present risks that

could lead to personal injury, loss of life, or property damage. Always
wear the appropriate personal protective equipment (PPE) for the job
Personal Protective at hand. Equipment that should be considered includes but is not
limited to:
Equipment
 Eye Protection
 Hearing Protection
 Hard Hat
 Gloves
 Safety Boots
 Respirator
Always read the proper Material Safety Data Sheet (MSDS) for any
working fluid(s) and comply with recommended safety equipment.

Be prepared to make an emergency shutdown when starting the

engine, turbine, or other type of prime mover, to protect against
runaway or overspeed with possible personal injury, loss of life, or
Start-up property damage.

On- and off-highway Mobile Applications: Unless Woodward's control

functions as the supervisory control, customer should install a
system totally independent of the prime mover control system that
Automotive monitors for supervisory control of engine (and takes appropriate
action if supervisory control is lost) to protect against loss of engine
Applications control with possible personal injury, loss of life, or property damage.

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Manual 26246 ProAct ISC

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.
Battery Charging
Device

Electrostatic Discharge Awareness

Prior to making any connections to the product, personnel should ensure that
they are free of electrostatic build-up in order to protect the integrity of the
device’s circuitry. The simplest method for dissipating electrostatic build-up is to
contact an adjacent, grounded metal object before contacting the product.

The product circuit boards should only be removed or repaired by

authorized Woodward personnel. In the event this is required,
authorized personnel must follow the ESD mitigation procedures
described in Woodward manual 82715, Guide for Handling and
Protection of Electronic Controls, Printed Circuit Boards, and
Modules, to ensure circuit board integrity is maintained during repair
or replacement.

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Regulatory Compliance
European Compliance for CE Marking:
These listings are limited only to those units bearing the CE Marking.

EMC Directive: Declared to Directive 2014/30/EU of the

European Parliament and of the Council of 26
February 2014 on the harmonization of the laws
of the Member States relating to electromagnetic
compatibility (EMC)

Other European Compliance:

Compliance with the following European Directives or standards does not qualify
this product for application of the CE Marking.

Machinery Directive: Compliant as partly completed machinery with

Directive 2006/42/EC of the European
Parliament and the Council of 17 May 2006 on
machinery.

North American Compliance:

These listings are limited only to those units bearing the CSA agency
identification.

CSA: CSA Certified for Class I, Division 2, Groups A,

B, C & D, T3 at 85 °C Ambient for use in
Canada and the United States.
Certificate 1167451
Type 3R Enclosure Rainproof

This product is certified as a component for use

in other equipment. The final combination is
subject to acceptance by CSA International (or
UL) or local inspection.

The ProAct™ ISC is suitable for use in Class I, Division 2, Groups A, B, C, and D
per CSA for Canada and US or non-hazardous locations only.

The ProAct ISC wiring must be in accordance with North American Class I,
Division 2 or Zone 2 wiring methods as applicable, and in accordance with the
authority having jurisdiction.

Field wiring must be suitable for at least 85 °C.

Connect the ground terminal of the ProAct ISC to earth ground.

I/O cabling for the ProAct ISC is limited to 30 m (100 ft) for surge compliance.

Compliance with the Machinery Directive 2006/42/EC noise measurement and

mitigation requirements is the responsibility of the manufacturer of the machinery
into which this product is incorporated.

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Manual 26246 ProAct ISC

EXPLOSION HAZARD—Do not connect or disconnect while circuit is

live unless area is known to be non-hazardous.

Substitution of components may impair suitability for Class I,

Division 2 or Zone 2 applications.

RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher

tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.

La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I,
applications Division 2 ou Zone 2.

Due to the hazardous location listings associated with this product,

proper wire type and wiring practices are critical to operation.

Do not connect any cable grounds to “instrument ground”, “control

ground”, or any non-earth ground system. Make all required
electrical connections based on the wiring diagram (Figure 1-4).

If the electronics are removed or disconnected form the actuator, the

calibration of the position has been lost. This calibration can only be
done at Woodward production.

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Chapter 1.
General Information

Purpose and Scope

The purpose of this manual is to provide the necessary background information
for applying the ProAct™ Integrated Speed Control (ISC) to diesel and gaseous-
fueled reciprocating engines. Topics covered include mechanical installation,
electrical wiring, software programming, and troubleshooting.

This manual revision applies to all ProAct ISC versions with software 5418-2374,
5418-2755, 5418-2949, or 5418-3777. The software part number is provided on
the Identification tab of the Service Tool. A configurable shutdown direction was
added to the 5418-2755 version, a configurable CAN baud rate is provided in the
5418-2949 version, and support for Model 4 EHT versions was added in the
5418-3777 version.

Intended Applications
The ProAct ISC control is designed for various industrial applications, including
but not limited to generator sets, mechanical drives, pumps and compressors.
The ProAct ISC is generally applicable to engines in the 300 kW to 1200 kW
output range. The ProAct ISC is a suitable replacement for mechanical systems
that need more flexibility in control strategy, such as dual dynamics, idle/rated
dynamics, and gain curves.

The ProAct ISC is CSA approved for Class I, Division 2, Groups A, B, C, and D
hazardous locations and is designed for on-engine mounting. Full ProAct ISC
specifications are listed near the end of this manual.

Introduction
The Woodward ProAct Integrated Speed Control (ISC) combines the proven
ProAct electric actuator with integrated speed control software to control the
speed of diesel and gaseous fuel engines. The ProAct ISC is a microprocessor-
based speed control incorporated into the actuator, creating a single integrated
actuator/speed control. This eliminates the need for an additional driver box and
speed control box.

The ProAct ISC can also be configured as a position control only for basic
actuator applications. The ProAct ISC position control accepts 4–20 mA, 0–5 V,
±3 V, or CAN position command signal.

The ProAct ISC control uses state-of-the-art speed sensing and control
algorithms. It also performs comprehensive diagnostics for easy troubleshooting.
The ProAct ISC is configured and tuned using the ProAct ISC Service Tool.

The modular bi-directional actuator design easily attaches to fuel pumps, fuel
valves, or throttle bodies.

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Basic Control Options

Position control with software support for:
 CW / CCW (clockwise/counterclockwise) direction control
 Field calibration options
Speed control with software selectable:
 Speed setpoints
 Dynamics
 Fuel Limiting
 Input/Output Definitions

Configurable Start / Stop behavior

Service Tool Software

The ProAct ISC Service Tool software is a Microsoft Windows® based GUI
(graphic user interface). The Service Tool Software is compatible with Windows
2000, XP. Vista, and 7 (32- and 64-bit) operating systems and gives the OEM the
ability to:
 Configure product settings based on application requirements
 Tune the control with the engine running during application development
 Create configuration files for downloading into multiple controls
 Download configuration files
 Extract and view fault codes for field diagnosis
 Update control dynamics during field service
 Calibrate the control for user stops

Detailed descriptions of software features and installation are available in

Chapters 4–7.

References

The actuator must be properly set up using the ProAct ISC Service
Tool prior to starting the prime mover.

The inertia setting and friction setting must be properly adjusted

using the ProAct ISC Service Tool prior to engine operation.
Improper inertia or friction settings can result in unpredictable
actuator movement and possible personal injury or damage to
equipment.

The Service Tool is not included, but can be downloaded from the
Woodward Internet website (www.woodward.com/software/).

The outline drawings are Figures 1-1, 1-2, and 1-3, and the control wiring
diagram is Figure 1-4.

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Manual 26246 ProAct ISC

Figure 1-1. Outline Drawing, Models I and II

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ProAct ISC Manual 26246

Figure 1-2. Outline Drawing, Model III

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Manual 26246 ProAct ISC

Figure 1-3. Outline Drawing, Model IV

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ProAct ISC Manual 26246

Figure 1-4. Control Wiring Diagram

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Manual 26246 ProAct ISC

Chapter 2.
Installation

Introduction
This chapter contains general installation instructions for the ProAct™ ISC
control. Power requirements, environmental precautions, and location
considerations are included to determine the best location for the control. The
control can be ordered as an actuator with speed control or as an actuator with
speed control and an Integrated Throttle Body (ITB).

EXPLOSION HAZARD—Do not connect or disconnect while circuit is

live unless area is known to be non-hazardous.

Substitution of components may impair suitability for Class I,

Division 2 or Zone 2 applications.

RISQUE D’EXPLOSION—Ne pas raccorder ni débrancher

tant que l’installation est sous tension, sauf en cas
l’ambiance est décidément non dangereuse.

La substitution de composants peut rendre ce matériel

inacceptable pour les emplacements de Classe I,
applications Division 2 ou Zone 2.

Due to the hazardous location listings associated with this product,

proper wire type and wiring practices are critical to operation.

Do not connect any cable grounds to “instrument ground”, “control

ground”, or any non-earth ground system. Make all required
electrical connections based on the wiring diagram (Figure 1-4).

Unpacking and Handling

Before handling the ProAct ISC, read the Electrostatic Discharge Awareness
information on page iv. Be careful when unpacking and lifting the ProAct ISC.
Check the ProAct ISC for signs of damage such as bent or dented covers,
scratches, and missing or broken parts. If any damage is found, immediately
notify the shipper.

Use both hands to pick up the ProAct ISC. Do NOT pick up by the
connectors or by the terminal shaft, which could damage the ProAct
or allow it to fall, with the possibility of personal injury.

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ProAct ISC Manual 26246

Mounting Location
The ProAct ISC is designed for installation on the engine. The mounting location
on the engine has to provide suitable access to the air throttle, fuel gas control
valve, or the diesel control shaft. The ProAct ISC must be able to change the
throttle, valve, or shaft position to control engine speed. Secondary mounting
location considerations are temperature, heat sink capability, vibration, and wire
length.

A minimum gap of 0.5 mm must be maintained between the support

bracket and electronics enclosure (see Figures 1-1, 1-2, & 1-3). This is
necessary because the enclosure is supported on vibration isolators
to filter out high-frequency vibrations from reaching the electronics. If
the enclosure contacts the bracket, the isolation is defeated and may
reduce the electronics operating life.
If spacers are used to achieve the necessary gap, Woodward
recommends maximizing the surface contact area of the spacers to
maximize heat transfer between the ProAct and mounting bracket.

Temperature
The ProAct ISC is designed to operate within a temperature range of –40 to +85
°C (–40 to +185 °F). However, maintaining the actuator operating temperature
near normal ambient temperatures (~20 °C) reduces the input and output
temperature drift and improves actuator life (MTTF).

Heat Sink Capability

The ProAct ISC generates heat, especially when stalled or during other
conditions requiring maximum torque output. The installer must consider the heat
conductivity of the installation bracket, and the operating temperature of the
ultimate heat sink to which the bracket will be attached.

The thermal design of the ProAct ISC is based on the cooling of critical electrical
components coupled to the aluminum frame of the actuator. If a temperature of
90 °C is maintained at the mounting surfaces, the temperature of the electronics
will remain within acceptable limits. Therefore, when applying the ProAct ISC, the
temperature at the mounting bracket must not exceed 90 °C regardless of the
surrounding thermal conditions. If the temperature of this zone exceeds 90 °C,
the actuator will limit the available torque to compensate.

The CSA hazardous location listing is not applicable if the

surrounding air ambient temperature exceeds 85 °C.

Mounting the ProAct ISC

Models I through III actuators may be installed on a bracket in either base- or
flange-mount configuration. Because of its mass, model IV requires that it be
mounted only in the base-mount configuration.

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Manual 26246 ProAct ISC
The base-mount configuration requires the use of four M8x1.25 screws with a
minimum engagement of 16 mm. The flange-mount configuration requires the
use of four M8 screws through the flange. Whether base mounting or flange
mounting the actuator, torque the four M8 screws to 22.6 Nm (200 lb-in). Both
mounting features are shown in Figures 1-1 through 1-3. The unit can be
mounted in any attitude. All exterior and mounting dimensions and exterior
fasteners are metric.

The brackets and attaching hardware must be designed to hold the weight and to
withstand the vibration associated with engine mounting.

The ProAct ISC weighs approximately:

Model I 11 kg (25 lb) Model II 11 kg (25 lb)
Model III 15 kg (32 lb) Model IV 24 kg (52 lb)

As shown in Specifications, the ProAct actuators have been designed for and
verified to a given accelerated life vibration test level at the mounting surface of
the actuator. The user should be aware that in any application, bracket design
can significantly change the vibration levels at the actuator. Therefore, every
effort should be made to make the bracket as stiff as possible so that engine
vibrations are not amplified, creating an even more severe environment at the
actuator. Additionally, when possible, orienting the actuator shaft parallel to the
crankshaft of the engine will often reduce the vibration load on the actuator's
rotor system in reciprocating engine applications.

Mounting the ProAct ISC with an ITB

The ProAct ITBs with model I and model II actuators are designed to be mounted
on the valve flange. However, the end-user may also want to support the
actuator to minimize the loads on their piping. The ProAct ITBs with model III and
model IV actuators are designed to be base-mounted due to the higher mass of
the actuator and the increased lever arm between the center of the bore and the
center of gravity. Flange mounting of model III may be allowed, but the vibration
level must be assessed in order to ensure a low level of stress on the
component.

Refer to the ITB manual for mounting details.

ProAct ISC Grounding

The ProAct ISC must be grounded to the engine structure through a low-
impedance connection in order to ensure proper EMC performance. This may be
accomplished through the mechanical mounting of the actuator/throttle itself
(preferred), or through a wired connection to a designated ground screw on the
unit. If a wired connection is used as the primary EMC ground, it must be through
a low-impedance wire or strap < 30 cm (12 inches) in length, 3 mm² (12 AWG)
minimum. See Figures 1-1, 1-2, and 1-3 for the ground screw locations on the
specific model versions.

Output Shaft
The ProAct ISC has 73–77° of available travel. The max fuel direction of this
travel is software configurable in the clockwise or counterclockwise direction
through the Service Tool.

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Mechanical Stops
Internal mechanical actuator stops will only survive a maximum kinetic energy of
0.011 J (0.097 in-lb). If the actuator internal stops are used, the load inertia
should not exceed 4.25E-4 kg-m² (3.76E-3 in-lb-s²). In service, electrical and
engine stops should be set inside the actuator stops. Electrical stops are set via
the Service Tool.

Fuel Position Stops

Diesel Stops—Diesel installations generally use the fuel system minimum and
maximum position stops. Diesel engine racks are normally designed to provide the
minimum and maximum stops without binding. The actuator's stops must not prevent
the actuator from driving the fuel linkage to the minimum and maximum positions.
The linkage should be designed to use as much actuator travel as possible, without
preventing minimum and maximum fuel positions (see Figure 2-1).

Gas Engine Stops—Fuel gas valves and butterfly valves in carburetors often
bind if rotated too far toward minimum or maximum. For this reason, the stops in
the ProAct ISC actuator should be used at both minimum and maximum
positions. Note that the actuator internal stops allow up to 1.5 degrees of
additional rotation in both directions during impact (see Figure 2-1). The engine
must always shut down when the actuator is at the minimum stop.

Figure 2-1. Fuel Stops

Linkage
Proper design and installation of the actuator linkage is necessary for the ProAct
ISC unit to provide the best possible speed control. Certain applications with low
inertia may be unstable with high impulse loads and may require additional
system inertia. See troubleshooting guidelines or contact Woodward for more
information. Ensure the actuator has ample work capacity to control the fuel
supply under maximum load conditions.

Manually stroke the fuel-control linkage from stop to stop as if the actuator were
moving it. The linkage must move freely, without friction and backlash. Lubricate
or replace worn linkage or fuel control parts as required.

The actuator contains no internal return spring; therefore an external

positive shutdown is necessary in the event of a loss of power to the
actuator.

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Manual 26246 ProAct ISC

The actuator’s maximum slew rate can place stress on the fuel
system stops and on the linkage between the actuator and the fuel
system. The maximum actuator speed is 1000 degrees per second in
both increase and decrease fuel directions.

The Mass Moment of Inertia (MMOI) for the ProAct ISC actuators:
 Model I and Model II is 5.5E-4 kg-m² (4.9E-3 lb-in-s²)
 Model III is 5.6E-3 lb-in-s² (6.4E-4 kg-m²)
 Model IV is 7.2E-3 lb-in-s² (8.2E-4 kg-m²)

The fuel system stops must be adequate to absorb the actuator MMOI in addition
to the linkage inertia without damage. ProAct actuator internal stops are
designed to absorb 0.011 J (0.097 in-lb) of kinetic energy with 1.5 degrees of
overtravel. If the actuator stops are used, the load inertia must not exceed
4.25E-4 kg-m² (3.76E-3 in-lb-s²), and the linkage must be designed to allow the
1.5 degrees of overtravel on each end. Use of good rod-end connectors with as
little free play as possible is essential. Select rod ends that will remain tight and
wear well during the nearly constant movement associated with precise speed
control. Low-friction, long-wearing rod ends are available from Woodward. The
link connecting the actuator lever to the fuel-control lever must be short and stiff
enough to prevent flexing while the engine is running.

GAS ENGINE STOPS—Fuel gas valves and butterfly valves in

carburetors often bind if rotated too far toward minimum or
maximum. For this reason, the stops in the ProAct ISC actuator
should be used at both minimum and maximum positions. Note that
the actuator internal stops allow up to 1.5 degrees of additional
rotation in both directions during impact (see Figure 2-1). The engine
must always shut down when the actuator is at the minimum stop.

Typically, in a linkage system, there are links and levers that are supported by
customer-supplied bearings. However, there is often a section of the linkage
where the mass is supported fully by the actuator output shaft. When designing
linkage systems, please note that each ProAct ISC actuator output shaft accepts
1.2 kg (2.6 lb) of additional mass at a maximum vibration level of 10 Gs.
Exceeding the allowable mass or vibration level may damage the actuator rotor
system and shorten actuator life.

Actuator levers are available from Woodward, which allow adjustment of the rod
end locations with respect to the center of the actuator shaft. The lever used
must have a 0.625-36 serration.

Adjust the location of the rod end on the lever to achieve the desired actuator
rotation between minimum and maximum positions. The linkage should be set to
use as much of the 75 degrees as possible (60 degrees minimum). To increase
the amount of actuator rotation, move the rod end closer to the actuator shaft or
farther away from the shaft controlling the fuel flow. To decrease the amount of
actuator rotation, move the rod end farther from the actuator shaft or closer to the
shaft controlling the fuel flow.

Electrical Connections
All input and output signals run through a 24-pin connector. Below is a
description for every pin and the electrical requirements. For functional
descriptions see Chapter 4, Description of Operation.

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Shielded Wiring
The use of cable with individually shielded-twisted pairs is required where
indicated by the control wiring diagram (Figure 2-2). Cable shields must be
terminated as indicated in the control wiring diagram using the installation notes
described below. DO NOT attempt to directly ground the shield at both ends,
since an undesired ground loop condition may occur. NOTE—The P-Series
actuator CAN shield connection pin is through a high-frequency capacitor only
(not directly grounded), therefore it may be grounded directly at the opposite end.

Installation Notes
 Wires exposed beyond the shield should be as short as possible, not
exceeding 50 mm (2 inches).
 The shield termination wire (or drain wire) should be kept as short as
possible, not exceeding 50 mm (2 inches), and where possible the diameter
should be maximized.
 Installations with severe electromagnetic interference (EMI) may require
additional shielding precautions. Contact Woodward for more information.
Failure to provide shielding can produce future conditions which are difficult
to diagnose. Proper shielding, when provided, at the time of installation is
required to assure satisfactory operation of the product.

The ProAct ISC is not supplied with the prime mover harness connector. The
following connectors are compatible with the ProAct ISC.

Amphenol
Amphenol Connector: P/N ACC 06E 24-28S (025)
Amphenol Contacts: P/N 10-597109-171 (CRIMP)
Amphenol Sealing Plugs P/N 10-405996-16

Cannon
Cannon Connector: P/N CA 06R 24-28S A206
Cannon Contacts: P/N 031-0560-161 (CRIMP)
Cannon Sealing Plugs: P/N 225-0017-000

As an option, a connector can be ordered from Woodward, part number

1635-1113, kit 6995-1021.

The correct size for all I/O wiring to the ProAct ISC is 0.5 mm² (20 AWG).

I/O cabling for the ProAct ISC is limited to 30 m (100 ft) for surge compliance.

Exceptions:
For specifics on power supply and the CAN wiring, see the Supply Power and
CAN Port Specification Summary sections later in this chapter.

Due to the hazardous location listings associated with this product,

proper wire type and wiring practices are critical to operation.

Do not connect any cable grounds to “instrument ground”, “control

ground”, or any non-earth ground system. Make all required
electrical connections based on the wiring diagram (Figure 1-4).

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Manual 26246 ProAct ISC

Supply Power (Pins: Z, Q)

Pin Z = Supply Power Plus ProAct Integrated Speed Control.
Pin Q = Supply Power Minus Input Power.

Reverse
The ProAct ISC requires a Z Voltage
Fuse Internal
Protection.
voltage source of 18 to 32 Vdc, Power Supply Power
with a current capacity of at Q Supply.
least:
5 A for the Model I
15 A for the Model II
15 A for the Model III
20 A for the model IV

If a battery is used for operating power, an alternator or other battery-charging

device is necessary to maintain a stable supply voltage.

Special care must be taken when wiring the ProAct ISC.

Figure 2-2. Correct and Incorrect Wiring to Power Supply

To withstand an engine start when control power is from the starting batteries,
the control will work with a supply voltage as low as 8 V. However, the control will
not function completely within specifications. During the low voltage, the ProAct
ISC will NOT meet the transient response times or the maximum torque output.

Voltage range
 Normal operation: 18–32 V
 Transient/starting: 8–40 V for 1 minute

The ProAct ISC must be fused:

 Model I: 5 A fast blow
 Model II: 15 A fast blow
 Model III: 20 A fast blow
 Model IV: 25 A fast blow

The input power must be fused. Failure to fuse the ProAct ISC could,
under exceptional circumstances, lead to personal injury, damage to
the control valve, or explosion.

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ProAct ISC Manual 26246
Wire Requirements:
For battery connections (+Bat and –Bat):
 Models I and II: 1.0 mm²/16 AWG for distances up to 8 meters
 Model III: 1.0 mm²/16 AWG for distances up to 5 meters
 Model IV: 1.0 mm²/16 AWG for distances up to 4 meters

Supply Power Specification Summary:

Name Value
Min voltage normal 18 V
Max voltage normal 32 V
Max extended voltage 40 V (1 minute)
Min extended voltage 8 V (limited performance)
Max current transient Model I < 3.5 A @ 18 V
Model II < 13 A @ 18 V
Model III < 15 A @ 18 V
Model IV < 20 A @ 18 V
Max current continuous Model I <2 A @ 18 V
Model II < 3.5 A @ 18 V
Models III & IV < 6.5 A @ 18 V
Max power steady continuous Model I - 36 W
Model II - 65 W
Model III - 73 W
Model IV - 101 W
Max power transient Model I - 67 W
Model II - 251 W
Model III - 282 W
Model IV - 371 W
EMC emissions EN 61000-6-4
EMC immunity EN 61000-6-2

MPU Input (Pins: R, S, W)

ProAct Integrated Speed Control.
Pin R = MPU plus signal M.P.U. (Speed) input.
Pin S = MPU min signal
Pin W = Shield (shared) R Edge
M.P.U. Voltage
The MPU input detects the S Detection
Prime Mover.
frequency of an MPU sensor W
typically pulsed by the flywheel ring
gear or holes in the flywheel. The
control calculates the engine speed
from this MPU input signal frequency. It also provides for displaying the MPU
voltage and status of the MPU input on the service tool.

Connect the MPU sensor between pins R and S. Pin R is the positive input signal
and pin S is for the negative input signal. The conductor shield must be
connected to pin W and the other side of the MPU sensor cable is not connected
and is isolated. The MPU and the RS-232 service port cables share pin W.

See Woodward manual 82510, Magnetic Pickups and Proximity Switches for
Electronic Controls, for information about MPUs and installation of the pickup
unit.

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Manual 26246 ProAct ISC
MPU Input Specification Summary:
Name Value
Min Voltage 1 Vrms
Will not detect rpm below. 0.5 Vrms
Max voltage 60 Vrms
Max frequency 24 kHz
Min frequency 1 Hz
Accuracy @ 24 kHz 1 rpm (> 3.9 sigma)
Accuracy @ 20 kHz 1 rpm (> 6 sigma)
Resolution clock 25 ns
Max teeth 400 teeth
Sample time 10 ms
Number of samples Software selectable

RS-232 Service port (Pins: Y, T, X, W)

ProAct Integrated Speed Control.
Pin Y = RS-232 TX Service Port Interface.
Pin T = RS-232 RX
Pin X = RS-232 Common T
Pin W = RS-232 Shield (shared) RS232
Y
Receiver
X
The RS-232 service port is used 3 2 5

to monitor, configure, and DB9

Connector.
W
troubleshoot the ProAct ISC. Use
a Windows operating system PC
to perform these typical functions:
 Monitor operations
 Calibrate the position control
 Tune prime mover dynamics
 Load or retrieve parameter settings from the control or a file
 Change a parameter setting for speed or position control

The ProAct Service Tool can be downloaded from the Internet at

www.woodward.com/software/.

The minimum specification for a laptop to run the service tool is:
 Windows 98, ME, NT, 2000, and XP operating systems
 300 MHz Pentium CPU
 64 MB RAM
 800 by 600 pixel screen
 Serial Port (RS-232)

It is recommended that the OEM or packager provide a breakout cable that is

connected to the ProAct ISC service port and run to an easily accessible area on
the engine. The service port is absolutely necessary to set up and troubleshoot
the ProAct ISC.

Discrete Inputs (Pins: F, B, A, L, E)

ProAct Integrated Speed Control.
Pin F = Discrete Input 1 Discrete Inputs.
High side switch. F
Pin B = Discrete Input 2
Pin A = Discrete Input 3 B
Fuse Discrete
Pin L = Discrete Input 4 Power Supply A Level
Used for the ISC Low side switch.
Pin E = Discrete Input 5 L detection.

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ProAct ISC Manual 26246
The Discrete inputs are used to control the behavior of the ProAct ISC from a
control panel or other control system components such as load share modules,
temperature controllers, oil temperature sensors, etc. There are five Discrete
inputs on the ProAct ISC control. The input functions (below) are mapped to
discrete inputs using the Service Tool. If desired, multiple functions can be
mapped to a single input.

The functions available for Discrete input configuration are:

 Run Enable Input
 Idle / Rated Input
 Rated 1 / 2 Input
 Raise Input
 Lower Input
 Alt Dynamics Input
 Isoch / Droop Input
 CAN ID Low Input
 CAN ID High Input

All five discrete inputs are the same electrical circuits. All five can be configured
in the software for high side switch or low side switch and for an active closed
contact or an active open contact.

High Side Switch: (default)

If used as a high side switch, the switch contact must be connected to the
discrete input pin and to the supply plus of the ProAct ISC. The high side switch
configuration is preferred.

Low Side Switch:

If used as a low side switch, the contact must be connected to the discrete input
pin and to the power supply minus of the ProAct ISC.

Active Closed: (default)

Active closed can be used for situations where it is safer to make the function
inactive if the wire is broken, or disconnected.

Active Open :
Active open contact can be used for situations where it is safer to make the
function active if the wire is broken, or disconnected.

The fuse shown in the diagram can be the same fuse that is used for the power
supply of the ISC—there is no need for an additional fuse.

Discrete Input Specification Summary:

Name Value
Low Level <4V
High Level >7V
Hysteresis >1V
Min Current @24 Volt > 1 mA
Max Current < 10 mA
Min Hardware delay > 2 ms
Sample Time 10 ms
Number of Samples 3
High / Low Side Switch Software Selectable
Active Open / Close Software Selectable

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Manual 26246 ProAct ISC

Discrete Output (Pin: K)

ProAct Integrated Speed Control.
Discrete Output.
Pin K = Discrete output K
Fuse Load.
Discrete
The discrete output is used Power Supply Output
Used for the ISC
to give a signal to a control Logic.
system or an operator Q
panel. In the software you
can determine when this
output is turned on or off.

The electrical circuit is a low-side switch with the return current going to supply
minus, pin Q. It is possible to drive a relay if more current is needed for the load.
If the load is below 0.5 A, the load can be driven directly from the output.

The user can turn the output on or off by the use of a number of Boolean flags
such as over speed, shutdown, alarm, etc.

The user can also configure a speed switch to turn the output on or off at specific
engine speeds. The MPU input provides the speed switch engine speed input.

The output is current protected and shuts down if driven above 0.5 A. If the short
is removed, the output returns to normal operation automatically.

Discrete Output Specification Summary:

Name Value
Max Current 0.5 A
Max Closed Voltage Drop < 1.0 V
Max Open Voltage 32 V
Overcurrent Protected Yes
Max Short Circuit Current 10 A Peak
Inductive Load Protection Yes
Switch Type Low Side
Sample Rate 10 ms

Analog Input (Pins: N, P, U, V, J)

ProAct Integrated Speed Control.
Pin N = Analog Input Plus Signal Analog Input.
Pin P = Analog Input Minus Signal
Pin U = 4 to 20 mA Select 1 Voltage, N
Current
Pin V = 4 to 20 mA Select 2 Source. ADC
P Bipolar,
Pin J = Shield (shared) Unipolar Converter
U
The Analog input can be used for V
Remote Speed Setpoint, Speed
Biasing, Load Sharing or Position J
control. The signal type is configured
by the wiring harness and software.

Connect the Analog Input sensor between pins N and P. Pin N is the positive
input signal and pin P is for the negative input signal. The conductor shield must
be connected to pin J and the other side of the Analog Input sensor cable is not
connected and is isolated. The Analog Input and the Analog Output cables share
pin J.

Mode: 0 to 5 V
If the input is used for 0 to 5 V, connect a voltage source between pins N and P.
Make sure that there is no connection between pins U and V. The signal at pin N
must be more positive then the signal at pin P.
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ProAct ISC Manual 26246
Mode: ±3 V
If the input is used for plus and minus 3 V, connect a voltage source between
pins N and P. Make sure that there is no connection between pins U and V. Pin P
will be seen as the reference voltage and pin N can go positive or negative.

Mode: 4 to 20 mA
If the input is used for 4 to 20 mA, connect a current source between pins N and
P. Make sure that pins U and V are connected as close as possible to the
connector. The signal at pin N must be more positive then the signal at pin P.

Analog Input Specification Summary:

Name Value
Accuracy @ 20 °C 0.05 % / FS (> 6 sigma)
Linearity @ 20 °C 0.5 % / FS (> 6 sigma)
Resolution 12 bits
(0–25 mA)
(0–5 V)
(–3–+3 V)
Temp drift. 200 ppm/°C
Sample Rate 10 ms
CCM @60 Hz or lower. 60 dB
CCM Voltage Range ±50 V
Input Impedance (Voltage mode) 100 kΩ
Input Impedance (Current mode) 200 Ω

Analog Output (Pins: H, D, J)

ProAct Integrated Speed Control.
Pin H = Analog Output Plus Signal AnalogOutput.
Analog Input.
Pin D = Analog Output Minus Signal
Pin J = Shield (shared)
H
DAC
The 4 to 20 mA analog output drives a 0 Ω Load
Conversion
to 450 Ω load. The high side (pin H) drives D
current from the internal power supply to
the load. Connect the return current to pin
J
D. Pin D is internally connected to the
power supply ground.

A shielded twisted-pair cable is recommended for the analog output. The output
can be setup in the software for scaling and output type.

Types supported are: the demanded position (setpoint), the actual position
(feedback), and the speed input (rpm signal from the MPU).

It is possible to use the analog output with more then one load if the total load
resistance is not greater than 450 Ω.

Analog Output Specification Summary:

Name Value
Accuracy @ 20 °C 0.05 % / FS (> 6 sigma)
Linearity @ 20 °C 1 % / FS (> 6 sigma)
Resolution (0–25 mA) 12 bits
Temperature Drift 450 ppm/°C
Sample Rate 10 ms
Max Load 0Ω
Min Load 450 Ω
Reverse Voltage Protection Yes

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Manual 26246 ProAct ISC

CAN Port (Pins: M, G, C)

ProAct Integrated Speed Control.
Analog
CAN Input.
interface.
Pin M = CAN High User Control
Pin G = CAN Low CAN High. M
Pin C = Shield CAN
120 ohms 120 ohms
Controller.
The CAN (Control
CAN Low. G
Area Network) link is
used for expansions CAN Common
C
to the control. There
is currently one application Q
determined; a J1939 CAN Position Control mode.

The use of a shielded twisted-pair cable is recommended for the CAN

communication. To prevent ground loops when there are more than two CAN
devices on the link, the shield connection is not hard wired to the chassis.
Termination is through a high-frequency capacitor.

The CAN link can support 11 Bit and 29 Bit identifiers, compatible with the 2.0A
and B standards. All controls on the CAN network must share the same battery
minus connection between the controls. If a control is used that has an isolated
output the isolated power minus signal must be connected to the battery minus of
the ProAct ISC.

The battery minus signal and the shield signal are not connected and therefore
cannot be used as a common signal between the controls. The shield should be
connected to the earth ground in the wiring harness to improve EMC
performance.

CAN Port Specification Summary:

Name Value
Wiring Specification ISO-11898
Max Wire Length 30 m
CAN Port Isolated No

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ProAct ISC Manual 26246

Chapter 3.
Description of Operation

General
The ProAct™ ISC is an electric actuator with position feedback and an integrated
digital speed control. Typically the actuator output shaft connects to the fuel gas
valve, intake throttle, or fuel oil pump rack shaft of a reciprocating engine. The
output shaft maximum rotation is 75 degrees and is configurable for CW or CCW
rotation. A manual mode is provided to facilitate setting up the actuator system.

The ProAct ISC can also be configured as a position control only for basic
actuator applications. The ProAct ISC position control accepts a 4–20 mA,
0–5 Vdc, or ±3 Vdc analog or a CAN position command input signal. A PWM
command input is not supported.

The speed setpoint can be adjusted by a remote 4–20 mA or 0–5 Vdc analog
input or by discrete inputs (such as Idle/Rated, Rated 1/Rated 2 selection, or
Raise/Lower).

For generator applications, isochronous load sharing and synchronizing

capability are available by a ±3 Vdc analog input in place of the remote 4–20 mA
/ 0–5 Vdc analog input. A compatible load sharing/synchronizer device is needed
to provide the load sharing/synchronizer input bias signal. Droop operation can
also be configured.

Control adjustments are made using the ProAct ISC Service Tool. The service
tool is a Windows based software tool provided at no charge to configure,
monitor, adjust, and troubleshoot a ProAct ISC speed control system. It runs on a
personal computer and communicates with the ProAct ISC speed control through
a serial connection. The service tool is disconnected from the control when not in
service.

The speed sensor input contains a tunable filter that minimizes the effects of
firing torsionals, which occur normally in reciprocating engines. This filter ensures
that the actuator does not react to speed sensor input changes produced by firing
torsionals. This provides exceptionally smooth steady-state speed control and
allows matching the control dynamics solely to the engine rather than detuning
dynamics for firing torsional frequencies. The control fails to the minimum fuel
position whenever the speed sensor signal is lost.

The control has a switching power supply with excellent spike, ripple, and EMI
(electromagnetic interference) rejection. Discrete inputs are capable of rejecting
EMI and variable resistance in switch or relay contacts. Analog inputs are
differential type with extra filtering for common-mode noise rejection.

The control provides one discrete output, which changes state based on
configurable alarms, status conditions or by a user configured speed switch.

The control provides one configurable 4 to 20 mA analog output. The

configuration choices are for engine speed, actuator setpoint or actuator position.
This analog output may be used with an analog meter, recorder, as input to
another control or to a computer.

20 Woodward
Manual 26246 ProAct ISC
The control provides one RS-232 serial interface and one CAN communication
connection. The RS-232 port is the service port used by the ProAct ISC Service
Tool to configure and tune the ProAct ISC system.

The CAN communication is used to connect to a remote control system.

Currently, the only option is for position control command input. Contact your
sales representative for future software updates to the ProAct ISC.

System Operation
The ProAct ISC actuator is ready for operation immediately (< 1 second) when
the power supply is connected. Power may be connected to the control at the
same time the engine starter motor is engaged.

On an engine shutdown command, the independent engine shutdown solenoid or

solenoid valve in the fuel supply should be de-activated and the power supply
disconnected from the speed control. This shutdown signal should be sent
directly from the engine control panel and should be independent and separate
from the ProAct ISC controller.

The ProAct ISC control should not be used as the primary means of
shutting down the engine.

Controller Features Description

As you review the following features, keep in mind that most applications only
require a few of the functions to be activated. The choices are made available to
provide maximum flexibility in a single package. The user must set up the
actuator direction, min and max fuel position calibration, speed input, setpoint
logic, and desired I/O. From the dynamics functions area, the user can set as
many or as few as is necessary for stable operation and acceptable load
transient response. The user can choose all or none of the fuel limiter functions,
speed setpoint modifiers, dynamic choices, alarm/shutdown functions and logic
functions depending on the application.

The controller I/O consists of input power, a speed input, one configurable analog
input, 5 configurable discrete inputs, one configurable analog 4–20 mA output,
one configurable discrete output and a CAN communication port (see Figure 1-
4).

Actuator Function
For Speed Control configurations, the Actuator Function converts the ProAct ISC
fuel demand into a specific actuator output shaft position. Position feedback is
included with the actuator function to assure positive positioning. The actuator
output shaft rotation is software configured for either a clockwise (CW) or
counterclockwise (CCW) output shaft rotation. For either rotation, the actuator
must be forward-acting (that is, the fuel delivered to the engine must increase as
the fuel demand increases). Reverse action is not supported; only reverse
rotation.

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ProAct ISC Manual 26246
For Analog and CAN Position Control configurations, all speed control functions
are disabled. In position configurations, the Actuator Function drives the ProAct
ISC actuator to maintain the position commanded by the supervisory control.
Position feedback is included with the actuator function to assure positive
positioning. The actuator output shaft rotation is software configured for either a
clockwise (CW) or counter-clockwise (CCW) output shaft rotation. An actuator
correction curve is provided to configure a demanded position versus actual
position for non-linear systems. The analog input can be configured to accept
4–20 mA, 0–5 Vdc, or ±3 Vdc position commands. PWM position commands are
NOT supported. Only Analog or CAN.

Speed Control Functions

The speed controller consists of a speed input, speed setting logic, speed
modifier logic, and speed dynamics options.

Speed Input
The ProAct ISC control accommodates one speed input from a magnetic speed
pickup (MPU) that provides a speed signal to the control. A digital type of
detection with firing torsional filtering is used for detecting engine speed. This
digital detection method senses speed very quickly for rapid response to speed
changes. The input frequency is converted to engine speed based on the gear
teeth. The Number of Cylinders to Average setting provides filtering of the speed
input.

Speed Settings and Ramps

The ProAct ISC provides for local speed setpoint control by discrete raise and
lower inputs. A 4–20 mA or 0–5 Vdc analog input provides for remote speed
setpoint control. A ±3 Vdc analog input provides for isochronous load-sharing
and synchronizer control. Input function must be configured to activate the
desired setpoint function.

The control also provides run, idle, and rated speed setpoints with a lower and
raise limit, plus accel and decel ramps, raise and lower ramps, and a ramp to
idle. All ramp rate settings are in rpm/sec, and all speed setpoint changes are
ramped for smooth setpoint transition. For emergency standby applications, a
very high ramp rate effectively cancels the ramp function to provide for rapid
starting. The Ramp to Idle determines how fast speed is increased from run to
idle speed. Accel rate determines how fast speed is increased from idle to rated
speed. Decel rate determines how fast speed is decreased from rated speed to
idle speed. The accel and decel rates are also used when transferring between
rated 1 and rated 2 speed settings. Raise and lower rates determine how fast
speed is increased or decreased by the raise and lower command inputs. Max
Analog Rate determines how fast the speed can be increased or decreased by
the remote speed setpoint input.

The Run Speed setting must be higher than cranking speed, but below the speed
attained while running on the start fuel position setting. The speed control
activates at run speed by grabbing the current operating speed as the initial
speed setpoint, then ramps the setpoint up to the idle speed setting at the Ramp
to Idle rate. If the idle/rated input is set in the rated position, acceleration passes
seamlessly through idle speed to the selected speed setpoint (rated, rated 1 or
rated 2) at the accel rate or to the analog speed setpoint at the max analog rate.

22 Woodward
Manual 26246 ProAct ISC

Speed Setting Priorities

The Run Speed Threshold has the highest priority and is the first speed setpoint
used during engine starting. The Idle setpoint has priority over the speed bias
functions (such as raise/lower, remote setpoint, load share input). The idle
setpoint must be unselected (rated setpoint selected) to activate the speed bias
functions. The Speed Bias functions have priority over the Rated Setpoint. For
example, if the remote setpoint is selected when the idle/rated input is switched
to the rated position, the setpoint will ramp to the remote setpoint rather than the
rated setpoint.

Speed Setting Options

The ProAct ISC has an array of options for monitoring and controlling engine
speed. The applications described here are just examples as there are many
more uses of the signals described.
 Changing Speed Setpoint
 Isoch/Droop

Changing Speed Setpoint

The ProAct ISC has multiple speed setpoint choices.

 Rated Speed Setpoint
 Idle / Rated Speed Setpoint
 Rated 1 or Rated 2 Speed Setpoint
 Raise/Lower Speed Modifiers
 Analog Speed Modifier
 Analog and Raise/Lower Speed Modifier

Rated Speed Setpoint—This is used for a system where a single speed setpoint
is sufficient. Speed is held constant at the rated speed setting. However, the fuel
limiters, run speed setting, and accel ramp are provided and active for light-off
and acceleration control up to rated speed. Typical applications are generator
sets where there may be no time or need to slowly start the engine. The engine
will go directly to the rated speed setpoint at the configured acceleration ramp
rate. Speed modifiers may be used to synchronize and load generator sets.

Idle/Rated Speed Setpoint—This feature allows the user to toggle the speed
setpoint between an idle and a rated speed. An Idle/Rated discrete input, is used
to toggle between the two speed settings. This input can be configured to select
Rated on either opening (active open) or closing (active closed) of the contact
input. The user can toggle between the two speed settings at any time during
operation. During transitions, the acceleration and deceleration rates are used.

Idle/Rated is commonly used to provide an idle speed setpoint for engine warm-
up or cool-down cycles. The idle speed setting is independent of the lower limit
setpoint and may be set at a lower speed. Idle speed cannot be changed except
by adjustment of the software setpoint. During starting, the idle speed setpoint is
selected when engine speed exceeds the run speed setting or while running
whenever the idle/rated contact is open (assuming an active closed
configuration). Closing the idle/rated contact ramps the speed setpoint from idle
to rated. Closing either the raise or lower contacts while ramping from idle to
rated immediately cancels the idle to rated ramp and speed follows the raise or
lower commands for variable speed control. No speed setpoint adjustments
(such as raise, lower, analog or droop) occur while running at idle speed.

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ProAct ISC Manual 26246
Rated 1 / 2 Speed Setpoint—The Rated 1 / 2 speed setpoint can be configured
in two ways.
 In the Startup Select Rated 1 / 2 configuration, discrete input 2 is sampled
before running, and selects either the Rated 1 or Rated 2 setpoint. Typically
this configuration is used to select between 50 Hz and 60 Hz operation in a
generator set application. Once engine speed reaches the run speed
setting, discrete input 2 has no effect until speed is below the stop speed
setting.
 In the Runtime Select Rated 1 / 2 configuration, discrete input 2 switches
between the Rated 1 and Rated 2 setpoints while running. This
configuration is typically used in a mechanical drive application where a two-
step speed control system is normal.

The Idle / Rated and Runtime Select Rated 1 / 2 configurations are similar in that
both offer two speed setpoints that can be selected by discrete input while
running. One difference is that with the Idle / Rated configuration, no speed
setpoint adjustments (such as raise, lower, and droop) are allowed during Idle
operation. The idle setpoint must be unselected (rated setpoint selected) to
activate the raise/lower and analog setpoints.

Raise and Lower Speed Modifiers—This feature allows the user to change the
speed setpoint with external discrete inputs. The raise and lower commands will
not adjust the speed setpoint above the raise limit nor below the lower limit.
 A lower command progressively decreases the speed setpoint down to a
configured lower limit at the configured lower rate for as long as the input is
in a high state (assuming the input is configured as active closed). When
this input goes low, the speed reference remains fixed at the last setting
reached the instant the input went low.
 A raise command progressively increases the speed setpoint up to a
configured raise limit at the configured raise rate for as long as the input is in
a high state (assuming the input is configured as active closed). When this
input goes low, the speed reference remains fixed at the last setting reached
the instant the input went low.
 Closing both the raise and lower discrete inputs selects the Analog Speed
Modifier, if configured.

Analog Speed Modifier—This feature allows the user to alter the speed setpoint
with an external signal. The input can be configured to function as a Remote
Speed Setpoint or for Load Share / Sync operation. The only difference between
these modes is how they affect the speed setpoint. The analog input is selected
when both the raise and lower inputs are activated. In analog mode the Max
Analog Rate is used to ramp analog input setpoint changes.

 Remote Speed Setpoint Operation

The Remote Speed Setpoint operates from 4–20 mA or 0–5 Vdc (jumper
configured). A direct or reverse acting remote speed setting can be
configured, using a normal or inverted input selection. Between 4–20 mA
and 0–5 Vdc, the control determines the speed setpoint based on a straight
line between the configured Low limit and High limit speed settings. See
Figure 3-1.

24 Woodward
Manual 26246 ProAct ISC

Figure 3-1. Remote Speed Setpoint Operation

It is recommended that the actual engine speed be used to externally

verify that the speed command matches the command signal sent.
Failure to comply with this recommendation can result in undetected
system faults.

 Load Share / Sync Operation

This input provides for synchronizing and isochronous load sharing within
generator systems. A compatible isochronous load sharing /synchronizer
control must be connected to provide the isochronous load
sharing/synchronizer functions. This input is active only when the ProAct
ISC is selected for isochronous operation.

Most Woodward Isochronous Load Sharing/Synchronizer controls operate

from –3 to + 3 Vdc. A positive voltage input increases the speed setpoint. A
negative voltage input decreases the speed setpoint. At zero voltage input
the speed setpoint stays constant.

The user configurable analog input must be scaled to match the Load
Sharing Module/Synchronizer used for these purposes. A DSLC™ load
sharing control typically requires a 3% of rated rpm speed setpoint change
per volt. An SPM-A or SPM-D synchronizer typically requires a 0.667% of
rated rpm speed setpoint change per volt. Other load sharing/synchronizer
controls may need different settings.

The user configurable max analog rate must be set very high (e.g. 1000
rpm/sec). The Isochronous Load Sharing/Synchronizer control must be
tuned for optimum stability and load transient response.

Analog and Raise/Lower Speed Modifier—This feature allows both analog

speed setpoint and raise/lower setpoint commands. When a Raise command is
activated, the setpoint increases, and when a Lower command is activated, the
setpoint decreases. When both the Raise and Lower inputs are activated the
Analog input is selected.

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 ProAct ISC Manual 26246
This feature is typically used in applications where the user needs manual control
over the engine speed during starting and stopping or special situations. After
completing the start/stop phase, or the special function, the analog input can be
selected for continuous automatic control of engine speed (e.g., flow, pressure,
temperature, etc.).

Isoch / Droop

The ProAct ISC speed control can be configured for either Isochronous speed
control or droop speed control. A discrete input can be configured to switch from
Isoch to Droop and back while the engine is running.

Isochronous (Droop OFF)—This is the default speed modifier function.

Isochronous operation maintains the engine at a constant speed setting
regardless of the load it is carrying. This mode is usually preferred for engines
driving compressors, pumps and for generator sets equipped with isochronous
load sharing controls.

For generator sets equipped with a compatible isochronous load sharing /

synchronizer control, Isochronous must be configured and the analog input must
be configured and connected for Load Share / Sync Operation.

Droop—Droop is used to reduce the speed setpoint as the actuator position

increases. This feature is primarily useful as an alternate means of loading a
generator set connected to a utility bus or paralleled with another genset on an
isolated bus. In this situation, the utility determines the frequency of the
alternator. During droop operation, increasing the speed setpoint causes the
generator to pick up load from the utility rather than increase generator
frequency. Droop is occasionally used in pump or compressor applications to
stabilize the engine speed.

Droop is a tunable value that decreases the speed setting when load increases
as determined by the actuator output position. Droop is set as a percentage of
rated speed (or Hz). Actuator positions must be entered for no-load and full load
to correlate the speed setting to load. A setting of 0% droop disables the Droop
function.

The desired engine speed reduces with the following formula:

speed reference * droop percentage * (actual position – no load actuator position)

(full load actuator position – no load actuator position)

The calculated speed offset is determined by the user-configured droop

percentage, no load actuator position, and full load actuator position settings.

Droop can be configured as always Off for Isochronous speed control, always On
for continuous Droop operation or to be switched On and Off during operation by
digital input.

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Manual 26246 ProAct ISC

Figure 3-2. Speed Droop

Speed Control Dynamics

The control algorithms used in the ProAct ISC are designed specifically for
reciprocating engine applications. The ProAct ISC speed control offers a
powerful set of dynamics that closely match a wide variety of fuel delivery
systems and applications. The following configuration choices are offered:

Rated Dynamics
If configured for Rated Dynamics, the gain remains constant as entered and does
not vary with engine speed or load. These are simplest dynamics and suit most
constant speed applications. Rated dynamics are typically used on engines that
operate continuously at rated speed or on variable speed engines that tend to be
stable at all speeds with constant dynamic settings.

Idle/Rated Dynamics
If configured, Idle/Rated Dynamics vary the gain with engine speed. Idle gain
applies when operating at idle speed. Rated gain applies when operating at rated
speed. The gain varies linearly at intermediate speeds and is limited by the idle
and rated gain settings at speeds below idle and above rated. Idle/Rated
dynamics are useful for variable speed engines that tend to be less stable at idle
speed when using the optimum rated speed dynamic settings.

Rated Dynamics Curve

A Rated Dynamics Curve varies the rated gain value with fuel demand (actuator
position). Fuel demand is roughly proportional to load but not necessarily in a
linear manner. A 5-breakpoint gain curve is provided to map gain versus fuel
demand. Gain is applied linearly between breakpoints. A common gain setting is
also provided to shift all gain curve gains higher or lower. This gain curve is
particularly useful for non-linear fuel systems (such as intake butterfly valves).

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Idle/Rated Dynamics Curve
When using an Idle/Rated Dynamics Curve, gain varies with both engine speed
and fuel demand (actuator position). Two separate 5-breakpoint gain curves are
provided to map gain versus fuel demand. The Idle Gain Curve applies when the
engine is operating at idle speed. The Rated Gain Curve applies when operating
at rated speed. The gain varies linearly at intermediate speeds and is limited by
the idle and rated gain curve settings at speeds below idle and above rated.
Separate common gain settings are provided for each curve to shift all gain curve
gains higher or lower. Idle/Rated Dynamics Curve is useful for non-linear fuel
systems that tend to be less stable at reduced speed and load operation when
using the optimum rated speed dynamic curve settings.

Integral and Derivative

For all dynamic configurations the Integral and Derivative settings are constant
and do not vary with either engine speed or load.

Dual Gain Settings

Gain Window and Gain Ratio settings further modify the applied gain. These
Dual Gain Dynamic settings can improve both steady state and transient load
performance by automatically switching between two gain settings. A low gain
setting is applied during steady-state operation. A high gain setting is applied
during load transients. Dual Gain Dynamics are available for all gain
configurations.

During steady-state loaded operation, the control uses the primary gain setting
(rated gain, idle /rated gain, etc.). In this region, gain is set to prevent the control
from responding to minor speed fluctuations inherent with reciprocating engines.
This essentially eliminates harmful jiggle of the actuator output and the fuel
system linkage during steady-state loaded operation.

During load transients, should the speed error exceed the adjustable Gain
Window width, the primary gain setting is multiplied by the gain ratio setting to
temporarily increase the applied gain. This higher gain produces a faster fuel
response to quickly restore engine speed to the speed setting. Speed error is the
difference between actual engine speed and the engine speed setting. The
primary gain setting is restored once the control senses a return to steady-state
operation (see Figure 3-3). Setting the gain ratio to 1 disables the function.

Figure 3-3. Control Gain as a Function of Speed Error

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Manual 26246 ProAct ISC
Dual Dynamics
The ProAct ISC speed control provides a complete second set of dynamic
adjustments (Dual Dynamics) that are selected by activating the 2nd Dynamics
discrete input. The control must be configured for Dual Dynamics to make these
settings available. Delay settings are available to delay switching dynamics when
the 2nd Dynamics discrete input changes state. These features are particularly
useful for engines where operating modes change, such as in dual-fuel or in
island/parallel generator applications since they provide for better stability during
mode transitions.

Start Fuel Limiting

Start Fuel Limit Function
Start Fuel is an adjustable position setting that limits the fuel demand during
engine starting to prevent over fueling. Two configurable start fuel choices are
available:
 Single Start Fuel
 Dual Start Fuel

Single Start Fuel—This configuration is suitable for most applications. With this
feature, the fuel demand immediately switches to the adjustable Start Fuel 1
position setting once the engine is cranking at the adjustable Start Speed 1
Threshold setting. The Start Fuel 1 position setting is removed and the fuel
control switches to normal speed control operation when the engine accelerates
above the Run Speed setting. Ramping functions are also enabled at this time.
The Run Speed setting must be set below the speed reached with the Start Fuel
1 setting. Setting the Start Fuel 1 position setting to 100 percent disables the
function. See Figure 3-4.

Figure 3-4. Start Fuel Limit

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Dual Start Fuel—This configuration is appropriate for engines that need a rather
high fuel setting to start the engine, but a much lower setting immediately
thereafter to minimize speed overshoot, black smoke, or to prevent an overspeed
shutdown. This feature is mainly beneficial for diesel engines. A tunable actuator
ramp rate provides a smooth transition from the Start Fuel 1 position setting to
the Start Fuel 2 position setting.

Dual Start Fuel provides a second start fuel function between the Start Speed 1
Threshold and Run Speed. Dual Start Fuel works like two sequential Start Fuel
position settings with a ramp between them. When Start Speed 2 Threshold is
reached, the Start Fuel 1 position setting is ramped to the Start Fuel 2 position
setting at the configured Actuator Ramp Rate. Setting this rate to its maximum
value effectively eliminates the ramp. Start Speed 2 Threshold must be set
higher than the Start Speed 1 Threshold setting. The Start Fuel 2 can be set
lower or higher than the Start Fuel 1 setting. See Figure 3-5.

Figure 3-5. Dual Start Fuel Limit with Ramp

Runtime Fuel Limiting

The Runtime Fuel Limit is a maximum position limiter on the fuel demand that
prevents overfueling/overloading after the engine has reached the run speed
setting. Four configurable options are available:
 Runtime Fuel Limiting
 Runtime Fuel Limiting with Transients
 Runtime (Speed-based) Fuel Limiting Curve
 Boost (External) Fuel Limiting

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Runtime Fuel Limiting
The Maximum Fuel Limit setting places a runtime maximum limit on the fuel
demand (actuator position). It is generally adjusted to prevent engine overloading
at rated speed or to merely limit fuel delivery to the engine for other situations
(such as, to prevent detonation). Adjusting the maximum fuel limit to 100 percent
disables the function.

Runtime Fuel Limiting with Transient

The Transient Fuel Limit setting allows a temporary increase to the fuel demand
above the Steady-State Fuel Limit setting for a limited time set by the Transient
Fuel Limit Time setting. This permits a lower steady-state fuel limit setting while
still providing an improved load-on transient response. The steady-state fuel limit
is restored once the transient fuel limit time period expires. The transient fuel limit
cannot be increased above 100 % fuel demand. The transient fuel limit is not
active below the Run Speed setting.

Runtime Fuel Limiting Curve

The Runtime Fuel Limit Curve is a software adjustable five-breakpoint curve
based on engine speed. The purpose of this fuel limiter is to prevent engine
overload during variable speed operation by mapping a fuel limit over the entire
speed operating range. The speed input provides the signal for this limiter
function. A fuel demand (actuator position) limit is set at each specific engine
speed breakpoint. The limiting value is linear between breakpoints as shown in
Figure 3-6. The engineering units for each breakpoint are in percent and rpm.
Each speed entry must be equal to or higher than the previous entry. The limiter
must be carefully set since excessive fuel limiting reduces load-carrying
capability. The runtime fuel limiting curve is not active below the run speed
setting.

Figure 3-6. Runtime Fuel Limiting Curve

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Boost (External) Fuel Limiting
The Boost Fuel Limit is a software adjustable five-breakpoint curve based on an
external analog input signal. Manifold Air pressure (MAP) is typically used for the
external fuel limiter signal. The purpose of the manifold air pressure fuel limiter is
to prevent over fueling during loading to significantly reduce black smoke in
diesel engine exhaust and unburned hydrocarbons in spark gas engine exhaust.
A fuel demand (actuator position) limit is set for each specific air manifold
pressure breakpoint.

The limiting value is linear between breakpoints as shown in Figure 3-7. The
engineering units for each breakpoint are in percent. The limiter must be carefully
set since excessive fuel limiting can degrade the loading response. Occasionally
exhaust temperature or other engine parameter is used for the external fuel
limiting function. The external fuel limiter is not active below the run speed
setting. Runtime Fuel Limiting is always active and can override a higher Boost
(External) Fuel Limit setting.

Figure 3-7. Boost (External) Fuel Limit

Analog Output
The analog output can be configured to show the actual position of the actuator,
position setpoint for the actuator or actual speed of the engine. This can be used
to connect to an engine tachometer, or to a control system for position control or
diagnostics.

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Discrete Output
The discrete output can be used to show a shutdown or alarm fault condition.
This can be used as a diagnostic signal for monitoring the engine. It can also be
used to shut down the engine using other means separate from closing the
actuator (0% position). The ProAct ISC discrete output can be configured to
monitor specific parameters in the system. This can help if there is application
specific trouble that must be monitored.

Temperature Sensing
The ProAct ISC has an on-board temperature sensor to monitor board
temperatures and protect the unit from over temperature and detect under
temperature. This temperature is monitored and a fault is annunciated if
temperature increases above 140 °C or falls below -45 °C.

Current Limiting based on Temperature

The control provides actuator current limiting based on the electronics
temperature. Dependent on board and actuator thermal models, the software
reduces current as necessary to avoid conditions that would damage the device
due to extreme temperatures.

Current limiting based on temperature begins when the combined current and
temperature environment causes board temperatures greater than 100 °C. The
steady-state limit curve is a linear derate from full current at 100 °C down to zero
current at 140 °C. Depending on the current (actuator torque) and ambient
operating temperatures, the unit may never reach a reduced current limiting
condition. See Figure 3-8.

Model II Current Limits Models' III, IV, and V Current Limits

14 25
Transient Current Limit
12 Transient Current Limit
20
Current (Amps)

10
Current (Amps)

15
8
Steady State Current Steady State Current
6 10

4
5
2

0 0
-50 0 50 100 150 -50 0 50 100 150
Temperature (deg C) Temperature (deg C)

Figure 3-8. Temperature vs. Current Limit

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ProAct ISC Alarms and Shutdowns

Power-up Diagnostics
The ProAct ISC provides power up self-test diagnostics. The power up
diagnostics takes less than one second to complete. This means that the speed
control is active within one second of power-up. A diagnostics error found during
power-up will shut down the control. There are a limited number of power-up
diagnostics, as most of the diagnostics are done during run time.

Run-time Diagnostics
Once power-up tests are completed, the unit starts controlling and provides
continuous indication of alarms and shutdowns. The ProAct ISC Service Tool can
be used to monitor the alarm and shutdown conditions. Also, the discrete output
can be configured to reflect internal shutdowns, overall alarm or shutdown status,
or individual alarms and shutdowns.

Alarm and Shutdown Actions

An alarm is intended to indicate a condition that an operator should be aware of
during operation or troubleshooting, but does not require the engine to be shut
down. Alarms are indicated on the service tool, and can be configured to
annunciate on the discrete output.

A shutdown means that the ProAct ISC will attempt to position the actuator at its
minimum position. Depending on the cause of the shutdown, the ProAct ISC will
perform one of two actions. If the shutdown cause allows the position control to
still operate properly (for example, a failed speed sensor), the position controller
commands the actuator to go to 0% position. If the shutdown cause does not
allow the position control to operate properly (for example, a position sensor
error), the actuator will be driven at the maximum steady-state current value to
the minimum position mechanical stop.

Alarm and Shutdown Indications on the Service Tool

Alarms and shutdowns are indicated on separate tabbed pages in the main
service tool screen. See further explanation on viewing the alarms and
shutdowns in the service tool by clicking on the Help menu item, then click
Contents. Select “Monitoring with the service tool” in the table of contents, and
click on the Viewing and Resetting Alarms and Shutdowns link. The alarm
and shutdown symbols on the status bar indicate the alarm and shutdown state
of the control. For example, if any alarms on the Alarm page are active, the alarm
symbol on the status bar is active.

Logged Alarms and Shutdowns

The occurrence of an alarm or shutdown is saved in non-volatile memory. If
power to the ProAct ISC is turned off, then turned on, the logged alarm and
shutdown indications can still be seen on the service tool.

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Resetting Alarms and Shutdowns

Alarm and shutdown faults can be globally set as either latching or non-latching.
When set to latching, either a reset command or a power-cycle is required to
clear the fault and allow the unit to start again. If non-latching, the fault is
automatically cleared without any reset once the fault condition returns to normal.

Alarms and shutdowns can be reset using the service tool, or by toggling the Run
Enable discrete input (if connected) Off for greater than 1 second, then back to
Run.

If a shutdown occurs when the control is in a state other than the Engine Stopped
state or Powered Down state, and then is immediately reset, the control remains
shut down until the Engine Stopped state is reached.

MPU Input Diagnostics

There are two diagnostics for the speed input that set the actual speed to zero
rpm and flag an error whenever the engine speed is above the speed detection
threshold at the time the diagnostic occurred. This threshold is defined as the
start speed threshold in legacy firmware versions but was increased to the stop
speed threshold in firmware version 5418-3777 B and newer.

If no MPU pulses were detected for 1.6 seconds, the speed sensor is considered
non-functional. As a result, engine speed will be set to zero. At low engine speed,
this does a satisfactory job of detecting MPU failures. At high engine speed,
however, this diagnostic is too slow.

The second diagnostic detects if the time between filtered engine pulses is
greater than 4 times the previous pulse. This method detects speed input signal
problems earlier at higher engine speeds.

Shutdown List
The following diagnostic conditions always cause a shutdown:

Watchdog Reset—The software was not executing properly and the

microcontroller was reset.

Speed Sensor Failed—There was a sudden loss of the speed signal.

Position Sensor Failed—An internal diagnostic check has determined that the
actuator position sensor has failed.

Overspeed—The configurable Overspeed Threshold was exceeded.

Maximum Starting Time—During starting, speed did not reach the Run Speed
Threshold before the Max Starting Time limit occurred.

Internal Shutdown—An internal failure has occurred. The Internal Shutdowns

page of the service tool indicates the exact cause.

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Configurable Alarm and Shutdown List

The following diagnostic conditions can be configured as an alarm, a shutdown,
or ignored (not enabled):

It is recommended that all faults be configured as shutdowns to

ensure maximum fault protection.

Power-up Reset—This indication goes true when power is first applied to the
ProAct ISC and remains true until reset.

Analog Input High—The analog input went above the analog input Diagnostic
Maximum threshold.

Analog Input Low—The analog input went below the analog input Diagnostic
Minimum threshold.

Input Voltage High—The input supply voltage went above 33 V.

Input Voltage Low—The input supply voltage went below 17 V. There is a delay
time before this indication occurs, to ensure that the control does not flag a
supply voltage low error during the standard engine start cycle.

Electrical Temperature High—The internal electronics temperature went above

140 °C.

Electrical Temperature Low—The internal electronics temperature went below

–45 °C.

Position Error—Indicates a difference between actual position and demanded

position was detected. The magnitude and duration values are customer-
configurable parameters (see Configuration, Position tab). This indication goes
true when the low-pass error delay filter on the ‘expected position minus actual
position’ is greater than the Error Maximum threshold setting. The filter time
constant is set by the Error Delay setting. The ‘expected position’ is internally
determined as the demanded position filtered by the expected dynamics.

Governor High Speed—The engine speed was higher than the Governing Error
High Range threshold for longer than the Governing Error High Time value. It is
an indication that the speed control is no longer controlling the speed of the
engine.

Governor Low Speed—The engine speed was lower than the Governing Error
Low Range threshold for longer than the Governing Error Low Time value. It is
an indication that the speed control is no longer controlling the speed of the
engine.

Not Run Enabled—The Run Enabled Input is disabled or has been commanded
Stop.

CAN Bus Off—The CAN Bus has not been commanded On or has been
commanded Off.

CAN Demand Too Slow—The CAN Bus is communicating slower than the
configured messages per second (msg.sec) rate.

CAN Demand No Signal—The CAN Bus demand input signal is lost.

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Manual 26246 ProAct ISC

Chapter 4.
Service Tool

Description
The ProAct Service Tool software is used to configure, tune, and troubleshoot
the ProAct ISC control. This chapter describes installation and use of the Service
Tool. It identifies the control parameters available for viewing.

Refer to Chapter 5 for comprehensive configuration instructions to set up the

ProAct ISC control for customer specific applications.

The Service Tool software resides on a PC (personal computer) and

communicates to the ProAct ISC through connector pins T, Y, X and W (see
Figure 1-4).

An RS-232 breakout cable is available for purchase from Woodward, part

number 1249-1147.

To PC (loaded
with Service Tool)

9-Pin Straight-
Thru Cable

Engine
Control
To ProAct Harness
Communication Harness
Actuator (Woodward 1249-1147)
VIS-198
2011-5-26

Figure 4-1. Communication Harness Connections

ProAct ISC
It is highly recommended that the Service Port Interface.
OEM or packager provide a
breakout cable for the ProAct ISC T
service port that is routed to a RS232
Y
Receiver
readily accessible area on the X
engine. The service port is 3
DB9
2 5
W
absolutely needed to set up and Connector
.
troubleshoot the ProAct ISC.

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The minimum specification for a laptop to run the service tool is:
 Windows 2000, XP. Vista, and 7 (32- and 64-bit) operating systems
 300 MHz Pentium CPU
 64 MB RAM
 800 by 600 pixel screen
 Serial Port (RS-232)

There is a potential for serial port damage when communicating with

the ProAct ISC control. This is caused by a difference in ac voltage
between neutral and earth ground. If the PC RS-232 port ground is
referenced to ac neutral, and the ProAct ISC control is referenced to
battery ground (ac earth ground), a large amount of current can be
experienced. To avoid this situation, we strongly recommend placing
an isolation transformer between the ac outlet and the PC.

Figure 4-2. Service Tool Screen Example

Getting Started
Installation Procedure
The Service Tool software can be downloaded and installed from the Woodward
Internet site (www.woodward.com/software/).

What to do next
After the software is installed, connect a serial communications cable between
the ProAct ISC breakout connection and an unused serial port on your computer.
Run the Service Tool program and select the appropriate comm port. Once
connected to the control, the status bar displays ‘connected’ and the Service Tool
screen populates with monitor parameters.

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Manual 26246 ProAct ISC

An unsafe condition could occur with improper use of these software

tools. Only trained personnel should have access to these tools.

Service Tool Help

More help on using the Service Tool is available and included with the installation
of the Service Tool product. Help can be accessed from the Service Tool
‘Contents’ drop-down selection under the Help menu located on the Main
Window.

Software Version Identification

The Service Tool software version is found by selecting ‘About’ under the Help
menu. The control software version is identified by ‘Software Part Number’ on the
Service Tool ‘Identification’ page. The Service Tool and Control must be
connected to view the control information. Refer to the control software version
and serial number in any correspondence with Woodward.

Monitoring the Driver

General
The Service Tool has five different tabbed screens to monitor driver parameters.
These are:
 Overview, (see Figure 4-3)
 Alarms, (see Figure 4-4)
 Shutdowns, (see Figure 4-5)
 Internal Shutdowns, (see Figure 4-6)
 Identification, (see Figure 4-7)

Displayed in an area above these screens are values showing the ProAct ISC:
 Control Mode
 Speed Setpoint
 Actual Speed
 Position Setpoint
 Actual Position

Control Mode
Displays the state of the ProAct ISC control, the present mode of the unit. States
include:
 Powered Down
 Engine Stopped
 Stopping
 Start Fuel 1
 Start Fuel 2
 Running Idle
 Ramping
 Running Rated 1
 Running Rated 2
 Ramping to Idle

See Appendix A for a full description of these Control Modes and the
State Diagram showing the transition between control states.

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Speed Setpoint
Displayed value of the speed setpoint - in rpm.

Actual Speed
Displayed value of the actual speed – in rpm.

Position Setpoint
Displayed value of the position demand - in percent.

Actual Position
Displayed value of the actual position - in percent.

Status Bar Indications

At the bottom of the Service Tool window is a status bar. The status bar has two
sections. The bottom left section displays communication status and bottom right
section displays alarm & shutdown status.

Communication Status
This section of the status bar shows the status of communication between the
service tool and the ProAct ISC control.
 Connected—The Service Tool is connected to and communicating with the
control.
 Not Connected—The Service Tool is not connected to the control.
 Connecting—The Service Tool is attempting to connect to the control. This
message is displayed when Connect is selected from the Communications
menu or when attempting to re-establish communication to the control. If the
connection is lost, it will continuously attempt to re-connect.

Alarms and Shutdowns

 Alarm Status
One or more alarms on the Alarms screen are active.
 Shutdown Status
One or more shutdowns on the Shutdowns or Internal Shutdowns screen
are active.

Overview Screen
To monitor the control parameters, go to the Overview page on the main window.
This screen dynamically populates based on the ProAct ISC configuration. If a
function is not programmed, it will not appear or may appear grayed out.

Analog Input
Displayed value of the analog input, in percent and rpm (if applicable).

Discrete Inputs
The overview screen displays the status of all discrete inputs. When the light is
“on” then the input is active. These status lights indicate the state of the input
regardless of whether the function (such as droop) is enabled or disabled.

MPU Input
Displayed value of the MPU input, in Vrms and Hertz, as read by the processor.

Dynamics
Displayed values of the actual dynamic settings used by the control.

Start Fuel Limit

Displayed value of the start fuel limit, in percent, as read by the processor.
Connection status to the position PID is also shown.

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Figure 4-3a. Service Tool—Overview Tab (Speed Control)

Figure 4-3b. Service Tool—Overview Tab (Position Control)

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Fuel Limit
Displayed value of the runtime fuel limit, in percent, as read by the processor.
Connection status to the position PID is also shown.

Boost Input
Displayed value of the boost input, in percent, as read by the processor.

Position Controller Output

Displayed value of the position controller output, in percent, as read by the
processor.

Estimated Current
Displayed value of the estimated input current, in amps, as read by the
processor.

Supply Voltage
Displayed value of the input power, in volts, as read by the processor.

Electronics Temperature
Displayed value of the electronics temperature sensor, in degrees Celsius, as
read by the processor. The temperature sensor is physically located on the
printed circuit board.

Analog Output
Displayed value of the analog output, in mA, as read by the processor.

Discrete Output
On/Off status of the discrete output command. The indicator is illuminated when
the channel is commanded to ON and grayed-out when the command signal is
OFF.

Shutdown and Alarm Indications

The Shutdown and Alarm screens display the status of both active and logged
fault conditions. The logged indications provide a history of events even after the
unit has been power-cycled or run again. A complete listing and detailed
description of all faults can be found in Chapter 3.

Indicates a logged alarm condition.

Indicates an active alarm condition.

Indicates a logged shutdown condition.

Indicates an active shutdown condition.

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An active fault is one that is currently active or latched in the control. The
latching/non-latching fault configuration setting factors into this indication. If the
fault is latching, then an active fault could either be one that is still present or one
that has occurred but has not been reset. Latched faults can be cleared by
cycling control power, toggling the Run Enable input or by selecting the ‘Reset
Alarms and Shutdowns’ button on either the Alarm or Shutdown service tool
screens.

A logged fault is one that has occurred but is no longer active or latched in the
control. Selecting the ‘Reset Logged Alarms and Shutdowns’ button on either the
Alarm or Shutdown screens permanently clears logged faults.

Alarms Screen
To monitor the alarm conditions, go to the Alarms page on the main window. The
values displayed on this screen dynamically change with the fault configuration.

Figure 4-4. Service Tool—Alarms Tab

Shutdowns and Internal Shutdowns Screens

To monitor the shutdown conditions, go to the Shutdowns and the Internal
Shutdowns pages (Figures 4-5 and 4-6) on the main window. The values
displayed on the Shutdowns screen dynamically change with the fault
configuration.

A Reset Alarms and Shutdowns command is available on the alarm and

shutdown screens to clear any faults that are currently latched on. If a fault
condition has occurred but is no longer present, it will remain as a logged fault
until cleared. The ‘Reset Logged Alarms and Shutdowns’ command clears all
logged faults.

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Figure 4-5. Service Tool—Shutdowns Tab

Figure 4-6. Service Tool—Internal Shutdowns Tab

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Identification Screen
To check the ProAct ISC product identification, go to the Identification screen.
Displayed information includes the ProAct ISC software part number and serial
number.

The Software Part Number identifies the embedded firmware part number and
revision level. The Serial Number is a Woodward tracking tool set at the factory.

Figure 4-7. Service Tool—Identification Tab

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Chapter 5.
Configuration

Introduction
This chapter describes the general steps required to configure the ProAct ISC as
a speed control on an engine or as a position control for actuator applications.
Whether the ProAct ISC is configured for speed control or position control, the
position controller setup is similar. The analog input or CAN input is the position
demand source for position control applications. The service tool guides the user
in calibrating and verifying the actuator stroke limits.

Information needed to set up the ProAct ISC for speed control:

 Type of engine (2 or 4 stroke)
 Number of cylinders for MPU input filtering
 Number of gear teeth on the engine where the speed input is sensed
 Idle Speed
 Rated Speed
 Overspeed threshold
 Max accel rate allowed from idle to rated speed
 Max accel rate allowed from starting to idle

There are three steps in setting up the ProAct ISC for speed control:
 Setup of the position controller
 Setup of the speed controller
 Setup of auxiliary signals

Overview
The ProAct ISC Service Tool is used to configure and adjust the settings within
the ProAct ISC. Refer to Chapter 4 for Service Tool installation and connection
instructions. The existing ProAct ISC control configuration settings can be viewed
at any time when connected to the control by opening the Configuration Editor
(File/Open Control Configuration).

The ProAct ISC can be configured either on-line or off-line. On-line configuration
can only be performed when the Service Tool is connected to and
communicating with the ProAct ISC control. Off-line configuration can be done at
any time; however, settings do not take effect until they are loaded into the
control.

The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.
The overspeed shutdown device must be totally independent of the
prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.

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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Configuring the Unit—On-Line

Unit On-Line configuration is summarized as follows:
1. Open the Configuration Editor Dialog by selecting ‘File/Open Control
Configuration’.
2. Edit the configuration settings.
3. Load the configuration to the ProAct ISC control.

As changes are made to Configuration parameters, the driver does

not use them until a ‘load’ command is issued. Selecting the ‘Cancel’
button closes the Configuration Editor and does not make any
changes to the driver.

Configuring the Unit—Off-Line

Unit Off-Line configuration is summarized as follows:
1. Open the Configuration Editor Dialog using the ‘File/New Configuration’ or
‘File/Open Configuration File’
2. Edit the configuration settings.
3. Save the configuration to a file. At a later date simply open the configuration
and load it into the control.

Configuration Parameters
There are 10 different screens that display the configuration settings in the
ProAct ISC speed control: Setpoint, Control, MPU Input, Modifiers, Fuel Limiting,
Dynamics, Analog I/O, Discrete I/O, Alarm/Shutdown, and Position. There are
two overall control type settings.

Control Type Setting

The Control Type setting determines whether the ProAct ISC functions as a
Speed Control or as an Analog or CAN Position Control (actuator only). This
setting also determines the display of additional configuration parameters.
Configuration settings are limited to those valid for the selected control type.

Speed Control
This selection sets the ProAct ISC to function as a Speed Control.

Analog Position Control

This selection sets the ProAct ISC to function as an Analog Position Control.

CAN Position Control

This selection sets the ProAct ISC to function as a CAN Position Control.

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Setpoint Tab
The setpoint tab provides the speed setpoint configuration settings.

Speed Setpoint Mode

The Mode determines how the speed setpoint functions. This setting also affects
the display of other configuration parameters.
Rated—Single speed setpoint control—at rated speed.
Idle / Rated—Two speed setpoint control, idle and rated. Must configure an
Idle/Rated discrete input to provide this function.
Start-up Select Rated 1/2—Setpoint uses 2 rated speeds, selected on unit
start-up. Must configure a Rated 1/2 discrete input to provide this function.
Runtime Select Rated 1/2—Setpoint uses 2 rated speeds, selectable at
any time. Must configure a Rated 1/2 discrete input to provide this function.
Idle / Rated 1 / Rated 2—Setpoint uses idle and 2 rated speeds, selectable
at any time. Must configure an Idle/Rated and a Rated 1/2 discrete input to
provide these functions.
Idle / Rated Input—Select the desired discrete input for the Idle/Rated
function.
Rated 1/2 Input—Select the desired discrete input for the Rated 1/2
function.

Idle Setpoint
Sets the Idle Setpoint. Only displayed if Idle is used. Allowed values: 0–4000
rpm, but must be less than Rated.

Rated Setpoint
Sets the Rated Setpoint. Only displayed if Rated is used. Allowed values:
0–4000 rpm, but must be greater than Idle.

Rated 1 Setpoint
Sets the Rated 1 Setpoint. Only displayed if Rated 1 is used. Allowed values:
0–4000 rpm, but must be greater than Idle.

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Rated 2 Setpoint
Sets the Rated 2 Setpoint. Only displayed if Rated 2 is used. Allowed values:
0–4000 rpm, but must be greater than Idle.

Acceleration Ramp Rate

Setpoint ramp rate, in rpm/sec, used when increasing to a rated setpoint. Allowed
values: 0.1–1000 rpm/s.

Deceleration Ramp Rate

Setpoint ramp rate, in rpm/sec, used when decreasing to a rated or idle setpoint.
Allowed values: 0.1–1000 rpm/s.

Ramp to Idle
Check to use the Ramp Rate to Idle. Leave unchecked to immediately raise the
speed setting to the Idle Setpoint as soon as the Run Speed Threshold is
reached.

Ramp Rate to Idle

Setpoint ramp rate, in rpm/sec, used when idle speed is selected. Only displayed
if Idle is used. Allowed values: 0.1–1000 rpm/s.

Control Tab
The control tab provides engine start and stop configuration settings.

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The ProAct ISC speed settings must abide by the following general order.

Starting the Engine

A typical engine starting sequence looks like this, if no shutdown faults are
detected:

1. When powered-up, the ProAct ISC control is in position control at the

configured min position.
2. If a Run Enable discrete input is configured, it must be enabled to start.
3. When the starter is engaged, the speed increases above the Start Speed 1
Threshold, and the controller positions the shaft to the Start Fuel 1 position
demand.
4. If two Start Fuel positions are used and speed increases above the Start
Speed 2 Threshold, the controller positions the shaft to the Start Fuel 2
position demand.
5. Once the engine speed is above the Run Speed Threshold, the controller
switches from the start fuel position demand to the speed controller PID
position fuel demand.

At this point, the unit is in speed control and controls engine speed at the
selected speed setpoint (Idle, Rated, Rated 1, or Rated 2). Setpoint ramping is
always active during speed control to ramp between setpoints. The PID position
is tracking the start fuel values during starting to provide a bumpless transfer
from start fuel control into speed control.

If a shutdown fault is detected, the control will drive the output to the calibrated
fail direction position.

Engine Starting Settings

Run Enable Input
Select the desired discrete input for the Run Enable function.

Start Fuel
Set to either one start fuel setting or 2 start fuel settings with a ramp between the
settings. A single start fuel is suitable for most applications. With this
configuration, the fuel demand immediately switches to the Start Fuel 1 setting
when the engine speed has exceeded the Start1 Speed setting.

Dual start fuel configuration is appropriate for engines that need a rather high fuel
setting to start the engine, but a much lower setting immediately thereafter to
minimize speed overshoot, minimize black smoke, or to prevent an overspeed
shutdown.

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Start Speed 1 Threshold
Start Speed 1 Threshold is set below cranking speed. Once this threshold is
exceeded, the control determines a start is in progress and opens the actuator to
the start fuel setting. At this point the governor state changes from ‘Stopped’ to
‘Start Fuel 1’. Typical value is 20 rpm to detect engine cranking.

Allowed values: 0–4000 but must be less than ‘Start Speed 2 Threshold’ (if used)
and less than the ‘Stop Speed Threshold’.

Start Speed Hysteresis

While in the Start Fuel State, hysteresis ensures that normal variation of engine
speed during cranking does not cause the control to drop back into the Stopping
state. Once the control reaches the Start Fuel state, it will enter the Stopping
state when engine speed drops below the (Start Speed 1 Threshold – Start
Speed Hysteresis) value. Allowed values: 0 to ‘Start Speed 1 Threshold’.

Start Fuel 1
Specifies the output shaft position when the governor state is ‘Start Fuel 1’. Value
is set to provide proper throttle or valve position for reliable starting. Allowed
values: 0–100%

Start Speed 2 Threshold

Specifies the speed at which the Governor State changes from ‘Start Fuel 1’ to
‘Start Fuel 2’ Typical value is 50% of the lowest speed reference. Only displayed
if two start fuel limits are configured.

Allowed values: Must be between ‘Start Speed 1 Threshold’ and the ‘Stop Speed
Threshold’.

Start Fuel 2
Specifies the output shaft position when the governor state is ‘Start Fuel 2’. Only
displayed if two start fuel limits are configured.

Allowed values: 0–100%

Actuator Ramp Rate

Specifies the rate, in %/s, the control will move the actuator position from the
Start Fuel 1 to the Start Fuel 2 position once the speed exceeds the Start Speed
2 Threshold. If the ramp rate is set to its maximum value, the change to the
second start fuel setting is nearly instantaneous, essentially eliminating the ramp
feature. Only displayed if two start fuel limits are configured.

Allowed values: 0.1 to 1000%/s

Max Starting Time

This is the maximum time the engine is allowed to stay within the Start Fuel
state. This is used to make sure that if there is a problem starting the engine, the
engine will be stopped after a reasonable amount of time.

Allowed values: 0–600 s

Run Speed Threshold

Specifies the speed at which the Governor State changes from ‘Start Fuel’ to
‘Run’. Typical value is 80% of the lowest speed reference. Setting must be above
cranking speed but below the speed achieved with the start fuel setting (light-off
speed). When the engine speed is above the Run Speed Threshold, the control
switches to one of the running states and begin using the speed control to drive
the actuator position demand.

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Allowed values: Must be greater than ‘Stop Speed Threshold’ and less than
4000.

Engine Stopping Settings

Power Down Time
Specifies the time the control remains in position control after the engine is
stopped and the run enable input is made inactive. Once in the Power Down
state, the control applies the Power Down Holding Current to the actuator.

Allowed values: 0–600 s

Power Down Holding Current

In the stopped state the control drives the actuator closed with the Stopped State
Holding Current. This is a percent value of steady state current of the actuator.
This acts like a return spring (electrical return spring) if the power to the actuator
is still available. This helps with diesel pump application or throttle application
where it is important to keep the actuator at the closed position while the engine
is stopped.

Allowed values: 0–100%

Steady state current and Torque of the actuators are:

Model I steady state current 3A
Model I steady state torque 1.3 Nm (11.5 lb-in)

Model II steady state current 6A

Model II steady state torque 2.6 Nm (23 lb-in)

Model III steady state current 10 A

Model III steady state torque 5.2 Nm (46 lb-in)

Model IV steady state current 10 A

Model IV steady state torque 10.4 Nm (92 lb-in)

The nominal torque produced by the actuator will be:

Actuator Current
Closing Torque   Steady State Torque
Steady State Current

where the actuator current is

Actuator Current  Power Down Holding Current %

100  Steady State Current

To determine the current draw from the battery in this holding mode, use this
formula:
1.2  ( Actuator Current ) 2
BatteryCur rent  0.8 
Battery Voltage

This is the nominal calculation at a battery voltage of 27 V. Depending on

temperature; the battery current can be different.

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Stop Speed Threshold
Specifies the speed at which the Governor State changes from ‘Stopping’ to
‘Stopped’. If the engine is stopped by a shutdown, the control will go to the
Stopping state and the engine must stop before proceeding to any other state. If
the engine is stopped by the Run Enable input, the control will again go to the
Stopping state. In this case, however, if engine speed is still above the Stop
Speed Threshold, making the Run Enable switch active again will allow the
control to go directly back to the running state. Below the Stop Speed Threshold,
the control does not allow the engine to go directly back to the running state.

Allowed values: Must be greater than the ‘Start Speed Threshold’ and less than
‘Run Speed Threshold’.

Stop State Delay

The Stopped State Delay setting delays the change from the Stopping state to
the Engine Stopped state (where the engine can be started again). This is done
to prevent starting the engine when it is still turning and the speed input has
failed. This time should be set to the time it takes the engine to come to a full
stop from the Start Speed 1 Threshold. Above the Start Speed 1 Threshold, the
speed signal loss results in a speed sensor failure, and the engine will not restart
until the control is reset.

Allowed values: 0–600 s

Error Detection Settings

Governing Error Low Range
Maximum error setting that triggers a Governing Error Low fault.

Allowed values: 0–4000 rpm

Governing Error Low Time

Governing Error Low speed range persistence, in seconds, prior to indicating a
fault.

Allowed values: 0–600 s

Governing Error High Range

Maximum error setting that triggers a Governing Error High fault.

Allowed values: 0–4000 rpm

Governing Error High Time

Governing Error High speed range persistence, in seconds, prior to indicating a
fault.

Allowed values: 0–600 s

Overspeed Threshold
Specifies the speed level that triggers an overspeed shutdown fault.

Allowed values: 0–4000 rpm, but must be greater than Rated.

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MPU Input Tab

The MPU Input tab provides the speed input configuration settings.

The MPU must be configured to ensure the control reads the correct
engine speed. A dangerous situation could result from incorrect MPU
input configuration since the ProAct ISC would sense speed
incorrectly and therefore not control the speed correctly. Also, the
internal ProAct ISC overspeed protection does not work properly if
the MPU input is incorrectly configured.

MPU Input Settings

2-Cycle
Specifies using the speed-sensing algorithm for a 2-cycle engine.

4-Cycle
Specifies using the speed-sensing algorithm for a 4-cycle engine

Number of Cylinders
Sets the number of engine cylinders.

Allowed values: 1—20

Number of Cylinders Averaged

Sets the number of cylinders to be averaged by the speed-sensing algorithm.
This setting is used as a filter to minimize the effects of firing torsionals that occur
normally in reciprocating engines. A lower value gives less filtering, increases
steady-state speed variation but allows for better transient response. A higher
value reduces steady-state speed variation but slows transient response.

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If unsure, set this to either ‘1’ or half the ‘Number of Cylinders’ for a 4-stroke. On
a 2-stroke engine, ‘1’ or ‘Number of Cylinders’ are good choices.

For uneven firing patterns, ‘Number of Cylinders Averaged’ should be set to

eliminate repeating torsionals.

Allowed values: 1 to ‘Number of Cylinders’.

Number of Teeth per Engine Revolution

Sets the number of teeth seen by the speed sensor during one engine revolution.
This value is used to calculate the engine speed based on MPU frequency.

Allowed values: 0.5–400.

Modifier Tab
The modifiers tab provides droop and speed setpoint biasing configuration
settings.

Droop Settings

Droop Mode
Determines what methods of adjustment of the speed setpoint are to be allowed.
Off–no droop is used, unit to remain in isochronous speed control.
On–actuator position droop is always enabled and active above Idle speed.
Digital Input–actuator position droop is enabled based on the droop
discrete input. If this is selected, a digital input must be configured for this
function

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Isoch/Droop Input
Select the desired discrete input for the Isoch/Droop function.

Droop
Sets the percentage of actuator position droop when droop is enabled.

Allowed values: 0–100%

No Load
Sets the no-load actuator position percentage for the droop function. Below this
actuator position the droop is zero.

Allowed values: 0% up to the ‘Full Load’ setting

Full Load
Sets the full load actuator position percentage for the droop function.

Allowed values: From the ‘No Load’ setting up to 100%

Bias Settings
Bias Mode
Determines which adjustment methods of the speed setpoint are to be allowed.
None–no biasing of the speed setpoint is used.
Raise/Lower–raise and lower setpoint adjustment commands are used.
Must configure raise and lower discrete I/O points to provide this function.
Analog–analog biasing of the speed setpoint is used.
Analog or Raise/Lower–a combination of raise/lower and analog biasing
are used to adjust the speed setpoint. Must configure raise and lower
discrete I/O points to provide this function.

Max Analog Rate

Specifies the maximum ramping rates allowed for the speed setpoint Analog
adjust function. Only displayed if Analog is configured.

Allowed values: 1–1000 rpm/s

It is recommended the Max Analog Rate setting be set to a value that

will prevent overshoot and possible overspeed on enabling of the
Remote Input.

Raise Input
Select the desired discrete input for the raise speed function.

Lower Input
Select the desired discrete input for the lower speed function.

Lower Rate
Specifies the ramping rate for the speed setpoint Lower function. Only displayed
if the Raise/Lower function is configured.

Allowed values: 0.1–1000 rpm/s

Raise Rate
Specifies the ramping rate for the speed setpoint Raise function. Only displayed
if the Raise/Lower function is configured.

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Allowed values: 0.1–1000 rpm/s

Analog Operational Mode

Determines how the analog input range is applied to the speed setpoint.
Load Share / Sync Operation–biasing is based on a percentage band
around the speed setpoint.
Remote Speed Setpoint–biasing values are set to a specific speed range.

Bias Limit
Specifies the maximum desired speed band possible, as a percentage of Rated,
with the Raise/Lower Adjust or Analog functions.

Allowed values: 0–100% of speed setpoint

Low Limit
Specifies the lowest desired speed setpoint possible with the Raise/Lower Adjust
or Analog functions.

Allowed values: From zero rpm to the ‘High Limit’.

High Limit
Specifies the highest desired speed setpoint possible with the Raise/Lower
Adjust or Analog functions.

Allowed values: From the ‘Low Limit’ up to 4000 rpm.

Fuel Limiting Tab

The fuel limiting tab provides run time fuel limiting configuration settings. If both
the runtime fuel limit and the boost fuel limit are configured, the Fuel Limit is the
lower of the two.

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Fuel Limiting Settings

Runtime Fuel Limiting
Determines the runtime fuel limiting mode.
None–No fuel limiters are used.
Runtime Fuel Limiting–a max actuator position is used to limit commanded
fuel position.
Runtime Fuel Limiting with Transients–a steady state and a transient fuel
limit is used.
Runtime Fuel Limiting Curve–a speed-based curve is used to determine
the fuel limit percentage.
Boost Fuel Limiting–an analog input, boost-based curve is used to
determine the fuel limit percentage.

Boost Fuel Limiting

Determines whether the boost fuel limit curve is used to limit the fuel based on
boost pressure or not.

Maximum Fuel Limit

Sets the maximum permitted shaft position. Only displayed if the mode is set to
either Runtime Fuel Limiting or Boost Fuel Limiting Curve.

Allowed values: 0–100%

Steady State Fuel Limit

Sets the maximum permitted actuator commanded position during steady state
conditions. Only displayed if the mode is set to Runtime Fuel Limiting with
Transients.

Allowed values: 0–100%

Transient Fuel Limit

Sets the maximum actuator position during a transient where the fuel demand is
above the Steady State Fuel Limit. Only displayed if the mode is set to Runtime
Fuel Limiting with Transients.

Allowed values: 0–100%

Transient Fuel Limit Time

Determines the length of time the Transient Fuel Limit is applied during a
transient. Only displayed if the mode is set to Runtime Fuel Limiting with
Transients.

Allowed values: 0–600 s

Speed (rpm)
Allowed values: Each breakpoint [5] must be larger than the previous and less
than the next value.

Limit (%)
Sets the maximum actuator positions for each breakpoint [5] based on the
current speed.

Allowed values: 0–100%

Boost (%)
Allowed values: Each breakpoint [5] must be larger than the previous and less
than the next value.

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Limit (%)
Sets the maximum actuator positions for each breakpoint [5] based on the boost
analog input.

Allowed values: 0–100%

Dynamics Tab
The dynamics tab provides speed control dynamic settings. The dynamic settings
can also be adjusted from the Edit Speed Dynamics screen during runtime.

Dynamics Settings
Overall Mode
Set to Single, Dual or Dual with Delay dynamics.

Alt Dynamics Input

Select the desired discrete input for the alternate dynamics function. Only
available when Dual Dynamics is selected.

Delay Switch (between Dyn 1 and Dyn 2)

The delay, in seconds, before the dynamics actually changes to the selected set
(either from dynamics 1 to dynamics 2 or vice versa).

Allowed values: 0–600 sec

Mode (Dynamics 1 and 2)

Sets the functional mode for the P-gain term of the PID. This can be individually
set for both sets of dynamics, if used.

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Rated–a single speed gain term is used which remains constant and does
not vary with engine speed or load. These are simple dynamics that suit
most constant speed applications. Rated dynamics are typically used on
engines that operate continuously at rated speed or on variable speed
engines that tend to be stable at all speeds with constant dynamic settings.

Idle Rated–the gain term is changed linearly between Idle and Rated
speed. Idle gain applies when operating at idle speed. Rated gain applies
when operating at rated speed. The gain varies linearly between the two
settings at intermediate speeds and is limited by the idle and rated gain
setting at speeds below idle and above rated. Idle/Rated dynamics are
useful for variable speed engines that tend to be less stable at idle speed
with optimum rated speed dynamic settings. Must configure an Idle/Rated
discrete input to provide this function (see Setpoint tab).

Rated Curve–the gain term is adjusted based on actuator position using a

5-pt curve. Fuel demand is roughly proportional to load but not necessarily
in a linear manner. A 5-breakpoint gain curve is provided to map gain versus
fuel demand. Gain is applied linearly between breakpoints. A common gain
setting is also provided to shift all gain curve gains higher or lower. This gain
curve is particularly useful for non-linear fuel systems (for example, intake
butterfly valves).

Idle Rated Curve–the gain is adjusted by using both actuator position and
speed. Must configure an Idle/Rated discrete input to provide this function
(see Setpoint tab).

Selection of Dynamics 2 curve options is only allowed if Dynamics 1

is also set to a curve option.

Integral
Speed control PID integral term in repeats per second.

Allowed values: 0–10 1/sec

Derivative
Speed control PID derivative term in seconds.

Allowed values: 0–5 sec

Gain Window
Speed control PID gain window, in rpm. When the speed error is greater than the
window, the Gain is multiplied by the Gain Ratio.

Allowed values: 0–4000 rpm

Gain Ratio
Speed control PID gain ratio. When the speed error is greater than the window,
the Gain is multiplied by the Gain Ratio. To disable the dual gain window, set the
Gain Ratio to 1.

Allowed values: 1–10

Rated Gain
Speed control PID gain term. This setting is applicable at rated speed.

Allowed values: 0.01–10 %/rpm

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Idle Gain
Speed control PID gain term. This setting is applicable at idle speed.
Intermediate gain settings apply at intermediate speeds between rated and idle.

Allowed values: 0.01–10 %/rpm

Position (%)
Position breakpoints for the gain curve.

Allowed values: Each point [5] must be larger than the previous and less than the
next value.

Range: 0–100%

Gain (%/rpm)
Sets the gain value [5] based on the position.

Allowed values: 0.01–10 %/rpm

Common Gain
Speed control PID common gain. This setting is a multiplier on the entire gain
curve settings. A Common Gain setting of 1 provides no bias for the curve
settings.

Allowed values: 0.01–10

Analog I/O Tab

The Analog I/O tab provides analog input and analog output configuration
settings. When the ProAct ISC control type is configured for analog position
control, the analog input is the position demand source. When configured for
speed control, the analog input may be configured as a speed modifier or as a
boost fuel limiter input. When configured for CAN position control, the analog
input is not available for use.

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Analog Input Selection

The analog input is scaled from input volts or mA to output %. It can be
configured as follows:
None–The analog input is ignored and does not affect the operation of the
ProAct ISC.
0–5 Volts–The analog input is a voltage input used as a remote speed
setpoint bias or as a boost fuel limit input or when configured, as the
position control command signal.
4–20 mA–The analog input is a current input used as a remote speed
setpoint bias or as a boost fuel limit input or when configured, as the
position control command signal.
±3 Volts–The analog input is a bipolar voltage input used for synchronizing
or load sharing.

Voltage Minimum
Specifies the lowest voltage used for the analog input voltage to the output
minimum percent scaling.

Allowed values: 0–5 Vdc

Voltage Maximum
Specifies the highest voltage used for the analog input voltage to the output
maximum percent scaling.

Allowed values: 0–5 Vdc

Current Minimum
Specifies the lowest current used for the analog input current to the output
minimum percent scaling.

Allowed values: 0–25 mA

Current Maximum
Specifies the highest current used for the analog input current to the output
maximum percent scaling.

Allowed values: 0–25 mA

Output Minimum
Specifies the lowest output percent used for the output minimum percent to the
analog input minimum voltage or current scaling.

Allowed values: 0–100 %

Output Maximum
Specifies the highest output percent used for the output maximum percent to the
analog input maximum voltage or current scaling.

Allowed values: 0–100 %

Diagnostic Minimum
Specifies the minimum normal value for the analog input. When configured, an
Analog Input Low alarm or shutdown fault is triggered when the input falls below
this setting.

Allowed values: -1 to 6 V or 0-25 mA

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Diagnostic Maximum
Specifies the maximum normal value for the analog input. When configured, an
Analog Input High alarm or shutdown fault is triggered when the input increases
above this setting.

Allowed values: -1 to 6 V or 0-25 mA

The user should ensure that the Diagnostic Minimum and Diagnostic
Maximum fields are set to values that will trigger an alarm or
shutdown when reasonable faults such as open or shorted wires
occur.

Analog Output Selection

The analog output is scaled from the position percent (actual % or setpoint%) or
the actual speed (rpm) to provide a current output from the ProAct ISC. It can be
configured as follows:
None–The analog output is turned off.
Actual Position–Sets the analog output to be an actual position output
signal.
Position Setpoint–Sets the analog output to be a position setpoint output
signal.
Actual Speed–Sets the analog output to be an actual speed output signal.
This selection is not available when configured for Analog Position Control.

Position Minimum
Specifies the lowest position % used for the analog output position percent to
output current minimum scaling. Setting the position minimum % higher than the
position maximum % is allowed to provide for a reverse acting signal as needed.

Allowed values: 0–100%

Position Maximum
Specifies the highest position % used for the analog output position percent to
output current maximum scaling.

Allowed values: 0–100%

Speed Minimum
Specifies the lowest speed used for the analog output speed to output minimum
current scaling. Setting a speed minimum rpm higher than the speed maximum
rpm is allowed to provide for a reverse acting signal as needed.

Allowed values: 0–4000 rpm

Speed Maximum
Specifies the highest speed used for the analog output speed to output maximum
current scaling.

Allowed values: 0–4000 rpm

Output Current Minimum

Specifies the lowest output current used for the analog output current to position
minimum % or speed minimum rpm scaling.

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Output Current Maximum
Specifies the highest output current used for the analog output current to position
maximum % or speed maximum rpm scaling.

Discrete I/O Tab

The Discrete I/O tab provides discrete input and discrete output configuration
settings.

Input Settings
Discrete Input function assignments are configurable. Each function can be
configured for activation by any of the five (5) discrete inputs. To make discrete
input assignments, see the Setpoint, Control, Modifiers, Dynamics and Position
tabs. The Discrete I/O tab shows the actual input assignments. All discrete inputs
can be configured for high side, low side, active closed, and active open contact
types.

In a typical engine harness, there is a higher likelihood of unintentional shorts to

battery minus than to battery plus. In such cases, using a high side setting
reduces the chance of a short causing unintended operation. The active open or
active closed setting for each input should be configured for safest operation. If
the most likely failure mode is an open wire, then configure the input to select the
safer engine operation should the wire break.

It is recommended that an engine system Failure Modes and Effects

Analysis (FMEA) be used to determine the discrete input
configuration that provides the lowest probability of unintended
operation in the presence of faults, such as a broken wire.

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High
If “High” input type is selected, the switch must provide a high voltage on the
input, typically a switch to battery plus.

Low
If “Low” input type is selected, the switch must provide a low voltage on the input,
typically a switch to battery minus.

Closed
If “Closed” active switch is selected, the function is active when the contact is
closed.

Open
If “Open” active switch is selected, the function is active when the contact is
open.

Output Settings
Relay Output Configuration
The relay output can be configured to one of the following:
None–The relay output is turned off.
On when selected faults become true–Sets the relay driver to turn on
when the selected fault becomes true and turns off when no fault conditions
exist.
Off when selected faults become true–Sets the relay driver to turn off
when the selected fault becomes true and turns on when no fault conditions
exist. This is the preferred, failsafe output configuration.
Speed Switch–Sets the relay driver to switch on and off at the configured
On Speed and Off Speed settings. Setting the On Speed rpm higher or
lower than the Off Speed rpm is allowed to provide for a reverse acting relay
output as needed.

Allowed values: 0–4000 rpm

It is recommended that the Relay Output be configured for the

failsafe ‘Off when selected faults become true’ mode, to ensure
maximum fault protection and annunciation. Failure to follow these
guidelines could, under exceptional circumstances, lead to personal
injury and/or property damage.

Relay Output Fault Selections

The list of faults displayed can be individually selected to activate the relay
output. A common selection is also provided to activate the relay output with any
configured Alarm or Shutdown fault.

Any of the selected faults will either turn the output off if configured for ‘Off when
selected faults become true’ or turn the output on if configured for ‘On when
selected faults become true’.

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A full description of each fault condition is listed in Chapter 3, Description of
Operation.
 Power-up Reset
 Watchdog Reset
 Analog Input High
 Analog Input Low
 Input Voltage High
 Input Voltage Low
 Electrical Temperature High
 Electrical Temperature Low
 Position Sensor Error
 Position Error
 Speed Sensor Failed
 Overspeed
 Governor High Speed
 Governor Low Speed
 Maximum Starting Time
 Not Run Enabled
 CAN Bus Off
 CAN Demand Too Slow
 CAN Demand No Signal

It is recommended that all faults be configured to activate the relay

output, this ensures maximum fault annunciation.

Alarm / Shutdown Tab

The Alarm/Shutdown tab provides alarm and shutdown configuration settings.

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Alarm / Shutdown Fault Settings

Fault Selection (Shutdown or Alarm)
Set the desired action for each of the faults from the list. Enable the faults that
are to be detected. Setting the selection to a Shutdown positions the output to
the minimum position when a fault occurs. Setting the selection to an Alarm
allows the unit to attempt continued running.

Fault Description
See Chapter 3 for detailed descriptions for the following fault conditions.
 Power Up Reset
 Analog Input High
 Analog Input Low
 Supply Voltage High
 Supply Voltage Low
 Electrical Temperature High
 Electrical Temperature Low
 Position Error
 Governor High Speed
 Governor Low Speed
 CAN Bus Off
 CAN Demand Too Slow
 CAN Demand No Signal

The following are dedicated shutdown conditions.

 Watchdog Reset
 Speed Sensor Failed
 Position Sensor Failed
 Overspeed
 Max Starting Time
 Internal Shutdown
 Not Run Enable

It is recommended that all faults be configured as shutdowns and

that ‘Enable Fault Latching’ be selected. This ensures maximum fault
protection and prevents erratic on/off fault behavior.

Enable Fault Latching

Set to either latching (checked) or non-latching. When set to latching, a reset
command or a power cycle must be issued to clear the fault. When non-latching
is configured, normal control operation is restored once the fault condition ceases
to exist. The fault log continues to indicate any faults that have occurred, but are
no longer active, until the logged alarms and shutdowns are reset.

Shutdown Direction (not available in 5418-2374 firmware)

Specifies the action when a shutdown condition is present. Options are: Go to
Min (0%), Go to Max (100%), or Go Limp (no drive current).

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Position Tab
This tab provides position configuration settings. Whether the ProAct ISC is used
for speed control, analog position control or CAN position control, the position
controller setup is similar. Only those settings applicable for the selected control
type are visible.

When the ProAct ISC control type is configured for analog position control, the
analog input is the position demand source. When the control type is configured
for CAN position control, the CAN input is the position demand source. When the
control type is configured for speed control, the position demand is driven by the
speed control function.

Dynamic Settings
Inertia Setting
The inertia setting calibrates the position controller to the load inertia. A setting of
zero represents the actuator shaft with no load attached. Higher load inertia
requires a higher inertia setting.

If the inertia setting is too low, there may be a slow oscillation when the actuator
should be steady, or the step response may show excessive overshoot and
ringing. If the inertia setting is too high, a high frequency oscillation or limit cycle
may be seen. If a range of values is seen to provide adequate response, the
lowest value that does not produce overshoot should be chosen.

See Position Calibration and Verification in Chapter 6 for more details and a
tuning procedure.

Allowed values: 0–20.

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Friction Setting
The friction setting represents the actuator current required to overcome static
load friction.

See Position Calibration and Verification in Chapter 6 for more details and a
tuning procedure.

Allowed values: 0–4.

Error Delay—Delay time setting before triggering a position error. Sets the time
constant of the single-pole low-pass which is filtering the difference between the
model-expected response and the actual sensed position. A position error may
be configured as an alarm, shutdown, or neither.

Allowed values: 0.5–10 sec.

Error Maximum Sets the maximum difference between the demanded position
and the actual position needed to trigger a position error.

Allowed values: 1-50 Degrees

Position Control Settings

Run Enable Input
Select the desired discrete input for the Run Enable function.

CAN ID Low Input

Select the desired discrete input for the CAN ID Low function.

CAN ID High Input

Select the desired discrete input for the CAN ID High function.

CAN Demand Too Slow Threshold

Sets the slowest allowable message per second rate prior to indicating a CAN
Demand Too Slow fault.
Allowed values: 10–100

CAN Data Rate (5418-2949 or newer firmware only)

Selects the desired CAN data rate. Options are: 125, 250, 500, or 1000 kbits/sec.
A power cycle is required before changes are effective.

Use Actuator Correction Curve

Check to use an Actuator Correction Curve. Leave unchecked for a linear
relationship between the position demand and actuator position.

Position Request (%)

Allowed values: Each breakpoint [5] must be larger than the previous and less
than the next value.

Actuator Position (%)

Sets the maximum actuator positions for each breakpoint [5] based on the
position request.
Allowed values: 0–100%

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Loading the Configuration (Save)

To load a configuration into the control, select the ‘File/Load to Control’ option
from the menu, the blue load to control arrow icon or hot keys ‘Ctrl+L’ on the
Configuration Editor. The ProAct ISC speed input must be zero to allow a ‘Load’
command.

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Chapter 6.
Setup, Calibration, and Tuning

Introduction
This chapter describes how to setup, calibrate and tune the ProAct ISC. The
service tool is used to configure, calibrate and tune the ProAct ISC. See Chapter
4 for service tool installation and connection instructions. The control must be
configured before it can be calibrated and tuned. The instructions in this chapter
assume the control has already been configured and installed on the engine. See
Chapter 5 for configuration instructions.

The following setup steps are required.

 Configure the Pro Act ISC control
 Calibrate the Position.
 Calibrate the Position Feedback range.
 Tune the Speed control loop PID.

These following optional setup features are also available:

 Verify Position calibration.
 Tune the Position control loop PID. For nearly all applications, the default
position gains DO NOT need to be changed. As a rule, tuning should be
limited solely to the speed control PID.

Some applications are delivered pre-configured, calibrated, and

tuned. For these applications, the configured gains rarely need to be
changed. Min Position and Fail Direction should be checked and
verified.

An unsafe condition could occur with improper use of these software

tools. Only trained personnel should have access to these tools.

Control Setup
Whether the ProAct ISC is used for speed control or simple position control, the
position controller setup is similar. When the ProAct ISC is used as a position
control, the analog or CAN input is the position demand source. When used as a
speed control, the analog input may be configured as a speed modifier or boost
fuel limiter input.

Use the service tool to set up the direction of rotation, either clockwise or
counterclockwise (CW or CCW), the 0 and 100% position feedback calibration,
and the dynamics. Ensure that the actuator linkage is set up to maximize the
actuator degrees of rotation. This results in better control resolution.

Make sure that the actuator output shaft moves freely from the 0% to 100%
positions and is not blocked by any linkage, mechanical stops, etc.

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Speed Control Setup

To setup the speed control, you must connect the ProAct ISC to the engine fuel pump,
throttle, or other device that controls the speed and power output of the engine. The
actuator direction must be set so that the 100% position is maximum fuel or power of
the engine, and the 0% position is minimum fuel or power of the engine.

It is highly recommended that the minimum fuel position setting stop

the engine. This is essential for any configured shutdowns in the
ProAct ISC to be directly effective. If this is not possible, the discrete
output should be configured to actuate an external shutdown device
as needed.

Position Control Setup

To set up the control for analog or CAN position control (actuator only), you must
connect the ProAct ISC to the driven device. The actuator stroke and direction
must set the 0% and 100% positions of the driven device to achieve the intended
control function.

Position Calibration and Verification

Position calibration maps the position command input (%) to the actual output
shaft rotation (degrees). It also sets the direction of rotation (CW or CCW).

There are two methods available to perform a position calibration:

Automatic—The actuator strokes itself to find the 0% and 100% positions
and saves these calibration points to the control.
Manual—The actuator shaft is manually positioned to the 0% and 100%
positions and these calibration points are manually saved to the control.

If the application has hard stops that correspond to the actual min/max travel,
then either the automatic or manual calibration method can be used—although
automatic is easier. If hard stops are not available, then the manual method must
be followed since the automatic method will yield invalid results.

Position Calibration and Verification Procedure

The service tool is used to calibrate end-user stops (physical or soft) and to verify
the position calibration.

Opening the Position Calibration Screen

Select ‘Position Calibration’ from the ‘Tools’ menu to open the ‘Position
Calibration’ screen. If the ProAct ISC is configured as a speed control, the engine
speed must be zero RPM before calibration can be performed.
Position Calibration
To calibrate the position, select either ‘Manual’ or ‘Automatic’. A “wizard” is
launched to guide the user through the calibration process. Click ‘Cancel’ at
any step to abort the calibration procedure without saving any new values in
the ProAct ISC.
Position Verification
To verify the position calibration without actually re-calibrating the position,
select ‘Verify Position’. A “wizard” is launched to guide the user through the
verification process.

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Manual Calibration Summary

1. Safety warnings are read, followed, and acknowledged.
2. The direction is set to CW or CCW rotation.
3. The actuator shaft is positioned to the desired 0% position point.
4. The actuator shaft is positioned to the desired 100% position point.
5. The inertia and friction values are set. See the instructions below on
“Adjusting the Inertia Settings” and “Adjusting the Friction Settings”.
6. To check the position calibration, change the position setpoint and verify that
the actual position is correct. The endpoints of travel can be adjusted if
needed.

Automatic Calibration
1. Safety warnings are read, followed, and acknowledged.
2. The direction is set to CW or CCW rotation.
3. The actuator strokes itself in the minimum direction, then in the maximum
direction.
4. The inertia and friction values are set. See the instructions below on
“Adjusting the Inertia Settings” and “Adjusting the Friction Settings”.
5. To check the position calibration, change the position setpoint and verify that
the actual position is correct. The endpoints of travel can be adjusted if
needed.

Click Next or Cancel.

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Adjusting the Inertia Setting

The inertia setting calibrates the position controller to the load inertia. A setting of
zero represents the actuator shaft with no load attached. The higher the load
inertia, the higher the required inertia setting.

The position calibration wizard provides an opportunity to test the settings. When
the Test button is pressed, the actuator will go to the 30% position, pause, go to
the 60% position, pause, return to the 30% position, pause, and go to the 0%
position. The actuator response to these steps helps determine the correct inertia
setting.

If the inertia setting is too low, there may be a slow oscillation when the actuator
should be steady, or the step response may show excessive overshoot and
ringing. If the inertia setting is too high, a high frequency oscillation or limit cycle
may be seen. If a range of values is seen to provide adequate response, the
lowest value that does not produce overshoot should be chosen.

Adjusting the Friction Setting

The friction setting represents the actuator current required to overcome static
load friction.

Where no spring return is present, the Input Current value should be increased
until the actuator just begins to move. That value of Input Current should then be
entered as the Friction Setting. Ideally, this should be done in the middle of the
travel range, and not at either end.

Where a return spring is present, the input current should be gradually increased
until the actuator begins to move against the spring, then gradually decreased
until it moves in the opposite direction. The Friction Setting should be one-half of
the difference between these two values. For example, if it takes 0.7 A to begin
moving against the spring, and at 0.5 A the actuator moves with the spring in the
opposite direction, set the Friction Setting at (0.7 – 0.5) / 2 = 0.1 A.

If the friction setting is too low, the actuator may not respond well to small
changes in the position demand. If the friction setting is too high, a high
frequency oscillation or limit cycle will be seen.

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Verify the Position Setting

A variety of Requested Position (%) values can be entered to verify the actuator
strokes correctly from the minimum to maximum positions. The Minimum Position
and Maximum Position settings can be adjusted, if necessary, to provide a more
precise setting at these two end positions.

Click Finish when position verification is completed. Repeat calibration if the

results are not correct.

Tuning the Speed Control Dynamics

The Service Tool is used to tune the Speed control PID, or to simply monitor /
trend the speed control behavior while the engine is running. The Speed control
dynamics must be tuned to achieve optimum speed stability and load transient
response. The trend display on the tuning screen is particularly useful for
monitoring the control performance and evaluating dynamic setting adjustments.

Opening the Tuning Screen

Select ‘Edit Dynamics…’ from the ‘Tools’ menu to open the speed control
dynamics adjustment screen. This opens a window that allows tuning the control
dynamics while running.

For details on the parameters that appear in this window, refer to Chapter 5.

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Help
Click the Help menu item, then Contents for additional information on using the
tuning window. In the table of contents, select “Making adjustments with the
service tool”, then click on the Adjusting Dynamics link.

Dynamics Tuning Precautions

When tuning the dynamics, it is best to start with a low gain. Always make sure
the engine emergency stop and the overspeed shutdown are working before
tuning and testing the control dynamics.

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Properties
Pressing the Properties button pops open the Properties Window. From this
window the user can adjust the trending window properties including the speed
range, position range, update rate and display range.

Start
Pressing the Stop/Start button toggles the trend operation. Press stop to freeze
the trend at its current display. Press start to re-activate the trend display. To
create a permanent record, use Alt, Print Screen to capture a current trend
display and paste it, for example, into a Word document. The trend cannot be
saved to a file or replayed.

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Chapter 7.
Software Upgrade Procedure

Introduction
The average user will need to install the ProAct™ ISC Service Tool as a
minimum to configure the ProAct ISC on a prime mover. In the event of a design
change, the user may be notified of a need to obtain new firmware. Installation
instructions follow.

Install Watch Window Professional

Go to the software section of the Woodward website
(www.woodward.com/software/) and get Watch Window Professional. Install
this according to the installation procedure for Watch Window.

Install ProAct ISC Service Tool

Go to the software section of the Woodward website
(www.woodward.com/software/) and get the ProAct ISC Service Tool. Install
this according to the installation procedure for the ProAct ISC service tool. The
latest service tool connects to older versions of software in the control.

Get the new firmware.

Contact your Woodward service person or sales person. The file you need has a
*.scp extension.

Update the firmware in the ProAct ISC.

 Watch Window Professional is used to update the firmware in the ProAct
ISC. Connect the control to a laptop or PC serial port. The cable is a one-to-
one cable (pins 2, 3, and 5 are used).

 Make sure the engine is stopped and the Run/Stop input is set into the Stop
state. If not, the control will not allow new software to be programmed.

 Get the parameter file out of the control by using the Service Tool. Save this
file to a disk.

 Update the firmware by using and following the programming instruction

from the watch windows tool.
o See the Watch Window Help for more details.
o Start the Server Select communication port, Point-to-Point, 38400 baud
rate.
o Start Watch Window after the service has connected and shows the
serial number of the control.
o Right click on the Serial Number tab and select in the menu Load
Application.
o Select the *.scp file to be loaded. It will warn you that it has an incorrect
name. Ignore this message. If the connection is lost, retry, and set the
service error to a longer time out and/or more retries.

The firmware is now updated.

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Chapter 8.
CAN Details

Overview
This chapter describes the communication that will take place over the SAE J1939
Data Link when the CAN (Controller Area Network) communication link is configured.

CAN Bit Timing

The default bit times for the ProAct™ ISC are configured per SAE J1939/11
section 3.14 (December 1994 version). The baud rate is 250 kbits/sec. The ability
to configure the baud rate was added in firmware version 5418-2949, where it
can be set from 125 kbits/sec to 1000 kbits/sec.

Source Address/Harness Code Strategy

There could potentially be four ProAct ISC actuators on the same engine. Each
actuator would need to have its own source address. Rather than having
separate sets of ProAct ISC software for each source address, a harness code
strategy has been implemented. The CAN address is set using the CAN ID Hi
and Lo discrete inputs. These switch inputs are pulled-up internally in the ProAct
ISC. The input will then either be left floating high, or be pulled down to ground
when the ProAct ISC is plugged in to the engine's wiring harness or wired
externally. The ProAct ISC actuator will read these switch inputs and assign the
appropriate source address on power up. Changes to the discrete inputs after
power up will not be acknowledged until the next power up.
ProAct ISC CAN ID Hi Bit CAN ID Lo Bit Assumed Source
Number (Configurable) (Configurable) Address of the ProAct
ISC Valve
#1 Floating high (open) Floating high (open) 19 13h
#2 Floating high (open) Pulled low 20 14h
#3 Pulled low Floating high (open) 21 15h
#4 Pulled low Pulled low 22 16h

Configuration Strategy
There are numerous configuration parameters available in the ProAct ISC. These
configuration parameters can either be downloaded as a file or individually
configured with the service tool. See Chapter 5. When required, these
parameters could be added as CAN PGNs and SPNs. However, at present there
are no plans to implement configuration over CAN until requested by a customer.

CAN Messages
The following information is sent over the CANbus:
 Actual and Desired Valve Position
 Heart Beat Counter
 ProAct ISC Software Version
 Alarms and Shutdowns (some grouping is provided to limit the number of
parameters)
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The following information is received from the CANbus:
 Position Demand

The following section lists all messages that will be sent by the ProAct ISC valve
to the engine control system.

Set 1 Transmitted Parameters

Valve Position
Description Value
Transmission repetition rate 100 ms
Data length 8 bytes
Data page 0
PDU format 255 FFh
PDU specific 251 FBh
Default priority 7
Parameter Group Number 65531 FFFBh

Byte: 1 Actual valve position

2 Desired valve position
3...8 Reserved

Actual Valve Position—Measured position. A value of 0% represents min and a

value of 100% represents max.
Data length: 1 byte
Resolution: 1/2.55% / bit, 0 offset
Range: 0 to 100% (scaled from 0 to FF hex)

Desired Valve Position—Desired position. A value of 0% represents min and a

value of 100% represents max.
Data length: 1 byte
Resolution: 1/2.55% / bit, 0 offset
Range: 0 to 100% (scaled from 0 to FF hex)
Error Indicator set if: None

Heart Beat Counter

Description Value
Transmission repetition rate 100 ms
Data length 2 bytes
Data page 0
PDU format 255 FFh
PDU specific 31 1Fh
Default priority 6
Parameter Group Number 65311 FF1Fh

Byte: 1,2 Heart Beat Counter

3...8 Reserved

Heart Beat Counter

Data length: 2 bytes
Resolution: 1 Count / bits, 0 offset
Range: 0 to 64255 Counts
Suspect Parameter Number: 1446-11

The Heart Beat Counter will count up.

Special action must be taken for the rollover from 64255 to zero.
Values above 64255 are not used, to be compatible with the J1939
specification.

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Software Version Number
If the engine control system needs the software version number it will use the
request message below.

Request Message
Description Value
Transmission repetition rate On request
Data length 3 bytes
Data page 0
PDU format 234 EAh
PDU specific ProAct address
Default priority 6
Parameter Group Number x EAxxh

Byte: 1 DAh
Byte: 2 FEh
Byte: 3 0h

Response Message
Description Value
Transmission repetition rate On request
Data length 8 bytes
Data page 0
PDU format 254 FEh
PDU specific 218 DAh
Default priority 6
Parameter Group Number 65242 FEDAh

Byte: 1 Number of software identification fields

Byte: 2...8 Software version or identifier. Data must be delimited with ASCII
“*”. Pad data with FFh if less than 7 characters.

Identification field
Data length: 1 byte
Range: 1

Software version number

Data length: 7 bytes (max of 6 bytes of data plus "*")
Range: ASCII characters, delimited by "*"
Resolution: 1 character/byte
Suspect Parameter Number: 234
Version Number Example: “1.01*”

The ASCII data must be displayed without formatting.

Diagnostics from ProAct ISC

The information communicated is limited to the current status of the diagnostics
and events that the ProAct ISC can perform within its scope. The status is bit
mapped to indicate the active or in-active state (see Bit Code Legend section).
Two bits are used for every fault condition to indicate the status. A proprietary
PGN will be used to communicate the faults.

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Diagnostics/Events
Request Message
Description Value
Transmission repetition rate On request
Data length 3 bytes
Data page 0
PDU format 234 EAh
PDU specific ProAct address
Default priority 6
Parameter Group Number x EAxxh

Byte: 1 10h
Byte: 2 FFh
Byte: 3 0h

The ProAct ISC will send the following Diagnostics and Events in a sequence.

Description Value
Transmission repetition rate 1 s*
Data length 8 bytes
Data page 0
PDU format 255 FFh
PDU specific 16 10h
Default priority 6
Parameter Group Number 65296 FF10h

* See Transmission Rate for details.

Diagnostic information must also be available by request from the En.

Byte: 1…4 Diagnostics

5...8 Events

Bit Code Legend

The ProAct ISC actuator will send the following diagnostics and events status in
a sequence.

Bit code Description

00 Inactive
01 Active
10 Reserved
11 Not Available

Bit position in a byte is “7 6 5 4 3 2 1 0”

Bit position 0 is least significant bit.
Example: Bit position 1 is “1” and all others bits are “0”; byte value is 2.

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Diagnostic Codes
J-1939 data frame
Diagnostics bit position
Run Enable Shutdown1 0,1
CAN Position Demand Failure 2,3
Internal Failure2 4,5
Internal Fault (Not Used) 6,7
Primary Demand Fault (Not Used) 8,9
Backup Demand Fault (Not Used) 10,11
General Alarm 12,13
General Shutdown 14,15
Reserved—Sent as “1” 16 to 31

1Available in firmware 5418-2949 and newer.

2InternalFailure includes the following shutdowns that are individually identified
in the Service Tool:
Shutdown—Main EEPROM Write Failure
Shutdown—Main EEPROM Read Failure
Shutdown—Parameter Error
Shutdown—Parameter Version Error
Shutdown—Sense 5 V Error
Shutdown—Sense Reference Error
Shutdown—Sense 15 V Error
Shutdown—Sense –15 V Error
Shutdown—A/D Converter Error
Shutdown—SPI A/D Converter Error
Shutdown—Watchdog Reset
Shutdown—Position Sensor Error
Shutdown—Speed Sensor Failed

Event Codes
J-1939 data frame
Events bit position
Position Error 32,33
High Temp Alert 34,35
Temp Limiting Active (Not Used) 36,37
24 Volt Supply High 38,39
24 Volt Supply Low 40,41
Low Temp Alert 42, 43
Powerup Reset 44, 45
Reserved—sent as “1” 46 to 63

Transmission Rate
The diagnostics messages are transmitted at a rate of once per second.

All the diagnostic and event bits are set appropriately to indicate their current
status. The engine control system will decode the bits, display the corresponding
diagnostic and event codes and log the diagnostic and event codes as required
by the application. The engine control system makes the decision to shutdown or
run depending on the application configuration, unless the ProAct ISC actuator
has already shutdown. The decision will be based on the diagnostic and event
classification made in the diagnostics document.

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Set 1 Incoming CAN Commands

This section lists all messages that will be sent by the engine control system to
the ProAct ISC actuator. The PGN for commanded position must be different for
each ProAct ISC and is determined by the ProAct ISC CAN address harness.

Commanded Actuator Position (Demand to ProAct ISC addresses 1–4)

ProAct ISC ProAct ISC ProAct ISC ProAct ISC

address 1 address 2 address 3 address 4
Description Value Value Value Value
Transmission > 5 ms > 5 ms > 5 ms > 5 ms
repetition rate
Data length 8 bytes 8 bytes 8 bytes 8 bytes
Data page 0 0 0 0
PDU format 255 FFh 255 FFh 255 FFh 255 FFh
PDU specific 22 16h 23 17h 24 18h 25 19h
Default priority 1 1 1 1
Parameter Group 65302 FF16h 65303 FF17h 65304 FF18h 65305 FF19h
Number

Byte: 1...4 Actuator Position Demand

5...8 Reserved

Valve Position Demand

Data length: 4 bytes
Resolution: 2.56E-8 %/bit, 5% offset
Range: –5 to 105 % (scaled from 0 to FFFFFFFF
hex)
Suspect Parameter Number: 1442

The resolution and range is a required deviation from the SAE

specification to meet application accuracy. Data is transmitted with
least significant byte first, per J1939.

Arbitration
Typical Arbitration field (information only) using 29 bits:

Example using Heart Beat Counter in Extension Set 1

Figure 8-1. Typical Arbitration Field Example

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Chapter 9.
Troubleshooting

Introduction

The actions described in this troubleshooting section are not always

appropriate in every situation. Always make sure that any action
taken will not result in loss of equipment, personal injury, or loss of
life.

The engine, turbine, or other type of prime mover should be

equipped with an overspeed shutdown device to protect against
runaway or damage to the prime mover with possible personal injury,
loss of life, or property damage.

The overspeed shutdown device must be totally independent of the

prime mover control system. An overtemperature or overpressure
shutdown device may also be needed for safety, as appropriate.

The ProAct ISC wiring must be in accordance with North American

Class I, Division 2 or Zone 2 wiring methods as applicable, and in
accordance with the authority having jurisdiction.

The ProAct™ ISC is used on prime movers that typically have a high
noise level. Always use appropriate hearing protection while working
around the ProAct ISC.

There are two parts to the troubleshooting section:

 Troubleshooting the ProAct ISC
 Troubleshooting Diagnostic Flags

The first section is used for situations where the system is not acting correctly,
but the ProAct ISC is not giving any diagnostic flags. The second section is used
if the ProAct ISC has diagnostic flags active.

Troubleshooting the ProAct ISC

Problem Description Possible Source Possible Action
The ProAct ISC is not There is no power supplied to the ProAct ISC. Check fuse, wiring, and battery voltage.
communicating with
the service tool. The wiring between the ProAct ISC and the Check wiring according to the wiring diagram.
laptop is incorrect.

The Service tool is disconnected. Connect the service tool by using the connect
menu.

The wrong communication port has been If connected, use disconnect and then re-
selected. connect with the correct communication port.

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Problem Description Possible Source Possible Action
The ProAct ISC is not The Run Enable input is not enabled. See Make sure the run enable input is made active.
opening the fuel overview screen on service tool. Check wiring.
control valve during
engine cranking. The ProAct ISC has detected a shutdown Reset the ProAct ISC by cycling power to the
situation and has not been reset. control, hitting reset on the Service Tool, or
toggling the run enable switch to off for 2
seconds and then back on again.

There is no power supplied to the ProAct ISC. Check fuse, wiring, and battery voltage.

The ProAct ISC does not read any speed. Fix or replace MPU, fix wiring or install MPU
MPU defect, wiring defect, or incorrect MPU correctly according to the MPU manual.
installation.

The ProAct ISC reads an actual engine speed Engine is cold and start speed is set too high.
below the start speed threshold. Lower start speed threshold.

The Start fuel 1 and or 2 setup is incorrectly Set up the Start Fuel to the correct value for this
set to zero position. engine.
The engine will not go The Idle Rated input wiring is defective. See Check wiring.
to rated speed. overview screen for input position.

The high, low, and active open or closed Set up the correct input modes.
selection for the Idle Rated input is selected
incorrectly.

The ProAct ISC is not configured for Idle Configure the ProAct ISC for Idle Rated
Rated operation. operation if that is the correct operation mode.
The engine will not go The Idle Rated input wiring is defective. See Check wiring.
to idle speed. overview screen for input position.

The high, low, and active open or closed Set up the correct input modes.
selection for the Idle Rated input is selected
incorrectly.

The ProAct ISC is not configured for Idle Configure the ProAct ISC for Idle Rated
Rated operation. operation if that is the correct operation mode.
The engine will not The Raise input wiring is defective. See Check wiring.
raise the speed overview screen for input position.
setpoint.
The high, low, and active open or closed Set up the correct input modes.
selection for the Raise input is selected
incorrectly.

The ProAct ISC is not configured for Raise Configure the ProAct ISC for Raise Lower
Lower operation. operation or Raise Lower and Analog if that is
the correct operation mode.

The Lower input is also active and the Analog Set up the lower input to the correct state. The
Raise Lower is configured. engine will not lower the speed setpoint.

The lower is active and only Raise Lower is Set up the lower input to the correct state. The
selected. The ProAct ISC will lower the speed engine will not lower the speed setpoint.
if Raise and Lower are selected at the same
time.

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 Manual 26246 ProAct ISC
Problem Description Possible Source Possible Action
The engine will not The Lower input wiring is defective. See Check wiring.
lower the speed overview screen for input position.
setpoint.
The high, low, and active open or closed Set up the correct input modes.
selection for the Raise input is selected
incorrectly.

The ProAct ISC is not configured for Raise Configure the ProAct ISC for Raise Lower
lower operation. operation or raise lower and analog if that is the
correct operation mode.

The Raise input is also active and the analog Set the lower input to the correct state. The
Raise Lower is configured. The control is in engine will not lower the speed setpoint.
analog mode.

Troubleshooting Diagnostic Flags

Error Flag Description Possible Source Possible Action
Power Up Reset The power up reset flag is Normal power up of the ISC. No action needed. Possibly
set every time power to reset control.
the ProAct ISC has been
lost and is restored. Loss of power or intermittent power Check wiring for bad or loss
supply wiring. connection.

Power supply wiring to long or to Make sure wiring is of the

thin. ISC will reset during transient correct thickness and length
power uses. according to manual.
Watchdog Reset If the watchdog has reset After software update, the software This is a normal situation. Reset
the ProAct ISC, this flag watchdog will reset the ProAct ISC. the error code and reset the
will set. stored errors.

The software is disrupted by EMI or This is an abnormal situation.

an internal component failure. Return the unit to Woodward.
Analog Input High This error flag will be set if Analog input is driven outside of the Check signal and fix incorrect
the analog input is higher diagnostic limit. signal level.
than the configured limit.
Diagnostic limit is setup incorrectly. Select correct diagnostic limit in
the ProAct ISC.

Analog wiring is shorted to a power Correct wiring problem.

source like the battery plus.
Analog Input Low This error flag will be set if Analog input is driven outside of the Check signal and fix incorrect
the analog input is lower diagnostic limit. signal level.
than the configured limit.
Diagnostic limit is set up incorrectly. Select correct diagnostic limit in
the ProAct ISC.

Analog wiring is shorted to a low Correct wiring problem.

signal like battery min.

Analog signal wiring is lost. Correct wiring.

The control that is driving the Turn on control or check

analog input is turned off or external controls manual for
damaged. troubleshooting.
Supply Voltage The power supply voltage Bad or damaged battery. Replace battery.
High is higher than the
diagnostic limits. Defective battery charging system. Fix battery charging system.

Incorrect setting of power supply Set correct voltage levels on

voltage level. power supply.

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Error Flag Description Possible Source Possible Action
Supply Voltage The Power supply voltage Defective battery charging system. Fix battery charging system.
Low is lower than the
diagnostic limits. Power supply wiring to long or to Make sure wiring is of the
thin. ISC will flag low voltage during correct thickness and length
higher power uses. according to manual.

Incorrect setting of power supply Set correct voltage levels on

voltage levels. power supply.
Electrical This error is set if the ProAct ISC has been placed in an Lower temperature by adding
Temperature High temperature inside the environment that is too hot. cooling, heat shielding, moving
control is higher than the unit, etc.
allowed by the
specifications. The internal temperature sensor is Return unit to Woodward for
defective. This can be determined repair.
by checking the temperature of the
unit and comparing this to the
service tool value of the electronics
temperature.
Electrical ProAct ISC has been place in an Increase temperature by adding
Temperature Low environment that is too cold. heat.

The internal temperature sensor is Return unit to Woodward for

defective. This can be determined repair.
by checking the temperature of the
unit and comparing this to the
service tool value of the electronics
temperature.
Governor High This error is set if the The actuator is not capable of Check the torque needed to
Speed actual speed if higher than closing the fuel control valve (max close the fuel valve against the
the speed setpoint plus a torque). available torque.
configured limit for longer
than the configured time. The fuel control valve is jammed or Fix or replace valve.
stuck.

The actuator is setup incorrectly. Run the position setup wizard to

Zero percent position will not set up the actuator correctly. 0%
completely close the fuel valve. will close fuel valve.

The linkage is moved or Fix or replace linkage.

disconnected.

The engine is not responding Check with the engine

correctly. troubleshooting manual.

The detection margins are set too Set the margins to an

low. acceptable level.

The detection time is set up too Set the detection time to an

short. A normal load transient will acceptable level.
trigger this error.

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 Manual 26246 ProAct ISC
Error Flag Description Possible Source Possible Action
Governor Low This error is set if the The actuator is not capable of Check the torque needed to
Speed actual speed if lower than opening the fuel control valve (max open the fuel valve against the
the speed setpoint minus torque). available torque.
a configured limit for
longer than the configured The fuel control valve is jammed or Fix or replace valve.
time. stuck.

The actuator is set up incorrectly. Run the position setup wizard to

100% position will not completely set up the actuator correctly.
open the fuel valve. 100% will open fuel valve.

The linkage is moved or Fix or replace linkage.

disconnected.

The engine is not responding Review the engine

correctly. troubleshooting manual.

The fuel supply to the engine is Open restriction in fuel supply,

restricted. check filters.

The load on the engine is too high. Reduce load on the engine to an
acceptable limit for this engine.

The detection margins are set too Set the margins to an

low. acceptable level.

The detection time is set up too Set the detection time to an

short. A normal load transient will acceptable level.
trigger this error.
Max Starting Time The max staring time error Start fuel is set too low. Engine will Set start fuel limit to a level
is set if the engine is not not reach run speed. where the engine will reach run
above run speed within a speed or lower run speed if a
configured amount of time. possible.

Low temperature of engine will not Select two start fuels with ramp
start engine at start fuel selected. to ramp to more or less fuel
during the engine start.

Engine is defective and will not Check with the engine

start. troubleshooting manual.

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Error Flag Description Possible Source Possible Action
Overspeed This diagnostic flag is set The overspeed parameter has not Set the correct overspeed value.
if the actual engine speed been set. Factory default is zero
is higher than the rpm.
overspeed threshold.
Engine dynamics are set up too Increase the gains, decrease
slow for a sudden load reject. gain window, or increase gain
ratio.

The actuator is not capable of Check the torque needed to

closing the fuel control valve (max close the fuel valve against the
torque). available torque.

The fuel control valve is jammed or Fix or replace valve.

stuck.

The actuator is set up incorrectly. Run the position setup wizard to

Zero percent position will not set up the actuator correctly. 0%
completely close the fuel valve. will close fuel valve.

The linkage is moved or Fix or replace linkage.

disconnected.

The engine is not responding Check with the engine

correctly. troubleshooting manual.
Speed Sensor This diagnostic flag is set Damaged, loss of MPU or wiring. Fix wiring or replace.
Failed if the MPU input pulses
have not been detected or Damaged or loss connector. Fix connector or replace.
the time between pulses
has changed by a factor of Incorrect installation of MPU Correct MPU installation. See
4, and the engine speed sensor. MPU installation manual.
was above the start speed
threshold. Make sure MPU teeth wheel is
Missing pulses on MPU teeth not missing any teeth’s.
wheel.
Position Error If the demanded position Incorrect inertia or friction settings. Check position dynamics using
and the actual position are the Service Tool. Click on Tools,
outside the configured then click on Position
limits. Calibration, and perform either
the manual or automatic position
calibration.

Binding or excessive friction in the Check all mechanical linkages

actuator linkage, or stops are set and stops.
inside the desired range of travel.
Position Sensor If the internal position Internal failure of position sensor. Return unit to Woodward.
Error sensor is outside the
diagnostic limits.
Internal Shutdown All internal shutdowns will The ProAct ISC is defective. Return unit to Woodward.
set this flag.
Main EE PROM The software can’t write to The ProAct ISC is defective. Return unit to Woodward.
Write Failure the EEPROM.
Main EE PROM The software can’t read The ProAct ISC is defective. Return unit to Woodward.
Read Failure from the EEPROM.
Parameter Error The software has detected You have upgraded the ProAct ISC Use the software upgrade
a checksum error on one software with an incompatible procedure to fix this problem.
of the parameter blocks. parameters set.

The ProAct ISC is defective. Return unit to Woodward.

Parameter The version of the The ProAct ISC is defective. Return unit to Woodward.
Version Error parameter set is incorrect.
Sense 5 V Error The 5 V power supply is The ProAct ISC is defective. Return unit to Woodward.
defective.

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 Manual 26246 ProAct ISC
Error Flag Description Possible Source Possible Action
Sense Reference The ADC reference voltage The ProAct ISC is defective. Return unit to Woodward.
Error is defective.
Sense 15 V Error The 15 V power supply is The ProAct ISC is defective. Return unit to Woodward.
defective.
Sense –15 V The –15 V power supply is The ProAct ISC is defective. Return unit to Woodward.
Error defective.
ADC Error The 10 bit ADC converter is The ProAct ISC is defective. Return unit to Woodward.
defective.
SPI ADC Error The 12 bit ADC converter is The ProAct ISC is defective. Return unit to Woodward.
defective.
CAN Bus Off This error is set if the CAN Incorrect or intermittent wiring Check wiring for broken or loose
Bus is not On. problem. connection.

Incorrect or missing termination Verify proper termination resistors

resistors. at the ends of the CAN network.

Electrical problems within the Possible problem with the

controller or unit. ProAct ISC, although additional
testing recommended before
returning to Woodward.
CAN Bus This error is set if the CAN Incorrect or intermittent wiring Check wiring for bad or lost
Demand Too Bus is communicating problem. connection.
Slow slower than the configured
messages per second Incorrect configuration. Verify configuration.
(msg.sec) rate
Device not sending updates fast Verify ECM messages and
enough or regularly (bursts). update rates. Verify configuration
of ProAct ISC min update rate.
CAN Demand No This error is set if the CAN CAN demand is missing (no Verify CANbus communication
Signal Bus demand input signal is signal). and connections.
lost.

Incorrect ProAct ISC Number. Check the CAN ID inputs to the

valve.

ECM is not sending Demand Verify that the ECM is powered

messages, or is not sending to the up and sending valid demand
correct ProAct ISC number. messages, and that the correct
ProAct ISC ID numbers are
selected.

CAN termination problem. Check if the CANbus has the right

termination resistor connected at
both ends of the bus.

CAN wiring problem. Check the CAN wiring for shorts,

open connections, interchanged
connections, and intermittent
contacts.

CAN noise problem. Verify that the CAN wiring is

installed according to the
installation instruction

CANbus incompatibility with ECM, Verify ECM CANbus

e.g., baud rate. compatibility.

CAN traffic overload. Verify that there is not excessive

CAN traffic that has higher
priority than the ProAct ISC
demand message.

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Chapter 10.
Product Support and Service Options

Product Support Options

If you are experiencing problems with the installation, or unsatisfactory
performance of a Woodward product, the following options are available:
1. Consult the troubleshooting guide in the manual.
2. Contact the OE Manufacturer or Packager of your system.
3. Contact the Woodward Business Partner serving your area.
4. Contact Woodward technical assistance via email
([email protected]) with detailed information on the
product, application, and symptoms. Your email will be forwarded to an
appropriate expert on the product and application to respond by telephone
or return email.
5. If the issue cannot be resolved, you can select a further course of action to
pursue based on the available services listed in this chapter.

OEM or Packager Support: Many Woodward controls and control devices are
installed into the equipment system and programmed by an Original Equipment
Manufacturer (OEM) or Equipment Packager at their factory. In some cases, the
programming is password-protected by the OEM or packager, and they are the best
source for product service and support. Warranty service for Woodward products
shipped with an equipment system should also be handled through the OEM or
Packager. Please review your equipment system documentation for details.

Woodward Business Partner Support: Woodward works with and supports a

global network of independent business partners whose mission is to serve the
users of Woodward controls, as described here:
 A Full-Service Distributor has the primary responsibility for sales, service,
system integration solutions, technical desk support, and aftermarket
marketing of standard Woodward products within a specific geographic area
and market segment.
 An Authorized Independent Service Facility (AISF) provides authorized
service that includes repairs, repair parts, and warranty service on
Woodward's behalf. Service (not new unit sales) is an AISF's primary
mission.
 A Recognized Engine Retrofitter (RER) is an independent company that
does retrofits and upgrades on reciprocating gas engines and dual-fuel
conversions, and can provide the full line of Woodward systems and
components for the retrofits and overhauls, emission compliance upgrades,
long term service contracts, emergency repairs, etc.

A current list of Woodward Business Partners is available at

www.woodward.com/directory.

Product Service Options

Depending on the type of product, the following options for servicing Woodward
products may be available through your local Full-Service Distributor or the OEM
or Packager of the equipment system.
 Replacement/Exchange (24-hour service)
 Flat Rate Repair
 Flat Rate Remanufacture

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Manual 26246 ProAct ISC
Replacement/Exchange: Replacement/Exchange is a premium program
designed for the user who is in need of immediate service. It allows you to
request and receive a like-new replacement unit in minimum time (usually within
24 hours of the request), providing a suitable unit is available at the time of the
request, thereby minimizing costly downtime.

This option allows you to call your Full-Service Distributor in the event of an
unexpected outage, or in advance of a scheduled outage, to request a
replacement control unit. If the unit is available at the time of the call, it can
usually be shipped out within 24 hours. You replace your field control unit with
the like-new replacement and return the field unit to the Full-Service Distributor.

Flat Rate Repair: Flat Rate Repair is available for many of the standard
mechanical products and some of the electronic products in the field. This
program offers you repair service for your products with the advantage of
knowing in advance what the cost will be.

Flat Rate Remanufacture: Flat Rate Remanufacture is very similar to the Flat
Rate Repair option, with the exception that the unit will be returned to you in “like-
new” condition. This option is applicable to mechanical products only.

Returning Equipment for Repair

If a control (or any part of an electronic control) is to be returned for repair,
please contact your Full-Service Distributor in advance to obtain Return
Authorization and shipping instructions.

When shipping the item(s), attach a tag with the following information:
 return number;
 name and location where the control is installed;
 name and phone number of contact person;
 complete Woodward part number(s) and serial number(s);
 description of the problem;
 instructions describing the desired type of repair.

Packing a Control
Use the following materials when returning a complete control:
 protective caps on any connectors;
 antistatic protective bags on all electronic modules;
 packing materials that will not damage the surface of the unit;
 at least 100 mm (4 inches) of tightly packed, industry-approved packing
material;
 a packing carton with double walls;
 a strong tape around the outside of the carton for increased strength.

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.

Replacement Parts
When ordering replacement parts for controls, include the following information:
 the part number(s) (XXXX-XXXX) that is on the enclosure nameplate;
 the unit serial number, which is also on the nameplate.

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Engineering Services
Woodward’s Full-Service Distributors offer various Engineering Services for our
products. For these services, you can contact the Distributor by telephone or by
email.
 Technical Support
 Product Training
 Field Service

Technical Support is available from your equipment system supplier, your local
Full-Service Distributor, or from many of Woodward’s worldwide locations,
depending upon the product and application. This service can assist you with
technical questions or problem solving during the normal business hours of the
Woodward location you contact.

Product Training is available as standard classes at many Distributor locations.

Customized classes are also available, which can be tailored to your needs and
held at one of our Distributor locations or at your site. This training, conducted by
experienced personnel, will assure that you will be able to maintain system
reliability and availability.

Field Service engineering on-site support is available, depending on the product

and location, from one of our Full-Service Distributors. The field engineers are
experienced both on Woodward products as well as on much of the non-
Woodward equipment with which our products interface.

For information on these services, please contact one of the Full-Service

Distributors listed at www.woodward.com/directory.

Contacting Woodward’s Support Organization

For the name of your nearest Woodward Full-Service Distributor or service
facility, please consult our worldwide directory published at
www.woodward.com/directory.

You can also contact the Woodward Customer Service Department at one of the
following Woodward facilities to obtain the address and phone number of the
nearest facility at which you can obtain information and service.

Products Used In Products Used In Products Used In

Electrical Power Systems Engine Systems Industrial Turbomachinery
Systems
Facility ----------------Phone Number Facility ----------------Phone Number Facility ---------------- Phone Number
Brazil -------------- +55 (19) 3708 4800 Brazil -------------- +55 (19) 3708 4800 Brazil -------------- +55 (19) 3708 4800
China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727 China ----------- +86 (512) 6762 6727
Germany: Germany ------- +49 (711) 78954-510 India--------------- +91 (129) 4097100
Kempen ---- +49 (0) 21 52 14 51 India--------------- +91 (129) 4097100 Japan -------------- +81 (43) 213-2191
Stuttgart -- +49 (711) 78954-510 Japan -------------- +81 (43) 213-2191 Korea -------------- +82 (51) 636-7080
India--------------- +91 (129) 4097100 Korea -------------- +82 (51) 636-7080 The Netherlands - +31 (23) 5661111
Japan -------------- +81 (43) 213-2191 The Netherlands - +31 (23) 5661111 Poland -------------- +48 12 295 13 00
Korea -------------- +82 (51) 636-7080 United States ---- +1 (970) 482-5811 United States ---- +1 (970) 482-5811
Poland -------------- +48 12 295 13 00
United States ---- +1 (970) 482-5811

For the most current product support and contact information, please visit our
website directory at www.woodward.com/directory.

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 Manual 26246 ProAct ISC

Technical Assistance
If you need to contact technical assistance, you will need to provide the following information.
Please write it down here before contacting the Engine OEM, the Packager, a Woodward
Business Partner, or the Woodward factory:

General
Your Name

Site Location

Phone Number

Fax Number

Prime Mover Information

Manufacturer

Engine Model Number

Number of Cylinders
Type of Fuel (gas, gaseous, diesel,
dual-fuel, etc.)
Power Output Rating
Application (power generation, marine,
etc.)
Control/Governor Information
Control/Governor #1

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Control/Governor #2

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Control/Governor #3

Woodward Part Number & Rev. Letter

Control Description or Governor Type

Serial Number

Symptoms
Description

If you have an electronic or programmable control, please have the adjustment setting positions or
the menu settings written down and with you at the time of the call.

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Appendix A.
ProAct ISC Control Modes

Introduction
An understanding of the ProAct ISC control modes is needed to properly set up
the control. The ProAct ISC Service Tool overview screen displays the active
control state. Transitions from one state to another are controlled by factors such
as engine speed, the discrete inputs, and the configuration settings. Depending
on the configured operating modes, the control will not always use all states. The
possible control states are described below.

State Descriptions

Powered
Down

Engine
Stopped

Start Fuel Stopping

Running

Stopping
The stopping state indicates the control has a shutdown fault and is driving the
output shaft position to the closed position. Once speed has reached zero rpm,
the control transfers to the stopped state.

Engine Stopped
In this state, the engine is stopped and the control is ready to begin the start-up
cycle if there are no active shutdowns. After the Stopped State Delay, the holding
current is applied to the actuator to limit the current draw and prevent battery
drain.

Powered Down
In this state, the actuator position control is turned off to drive the actuator to a
0% position and the holding current is applied to limit the current to the actuator.
If the actuator can move past the 0% position, it will, and a negative position will
be indicated.

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Start Fuel 1
The Start Fuel 1 state is selected once the engine speed goes higher than the Start
Speed 1 threshold. In this state, the actuator position is set to the Start Fuel 1 value.

Start Fuel 2
The Start Fuel 2 state is selected once the engine speed goes higher then the
Start Speed 2 threshold. In this state, the actuator position is ramped to the Start
Fuel 2 value. This state is only used if two start fuels are selected.

Ramping to Idle
Indicates the speed setpoint in ramping up to idle speed setpoint during a start
sequence. Ramping to idle only happens if configured for Idle / Rated. This state is
selected once the engine speed goes higher than the run speed threshold. At the
moment this state is entered, the control captures and sets the actual engine
speed as the speed setpoint, then ramps to the idle set point at the ramp to idle
rate.

Running Idle
Indicates the speed setpoint is at the configured Idle speed setting. To leave this
state, the rated command must be issued.

Ramping
The ramping state is used to ramp from one set point to another set point. If the
setpoint is switched between Idle and Rated or Rated 1 and Rated 2, we will use this
state to ramp with the acceleration or deceleration ramp rate. If Raise or Lower are
momentarily selected (halt), the ramp will stop and the setpoint will remain at the last
position. The setpoint can be adjusted from this point using the Raise/Lower
commands. If the halt command is selected when ramping from idle to rated and the
setpoint is below the normal adjustment range, the setpoint will continue to ramp and
then halt at the minimum setting of the speed adjustment band.

Running Rated 1
Indicates the unit is running at the Rated 1 set point or the changed Rated 1 set
point if raise, lower, or analog control is used.

Running Rated 2
Indicates the unit is running at the Rated 2 set point or the changed Rated 2 set
point if raise, lower, or analog control is used.

State Transitions
Powered Down State
The control changes from this state to the Engine Stopped state when:
 The Run Enable switch is active.

Engine Stopped State

The control changes from this state to the Start Fuel state when all of the
following are true:
 Engine speed exceeds the Start Speed 1 Threshold
 The Run Enable switch is active
 The control is not shutdown
 The speed setpoint is not zero

The control changes from this state to the Powered Down state when both of
the following are true:
 The Run Enable switch is not active
 The Power Down Delay time period has elapsed

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Start Fuel State
If one start fuel is configured, the Start Fuel state is simply the Start Fuel 1 sub-
state described below. If two start fuels are configured, it consists of the Start
Fuel 1 and Start Fuel 2 sub-states.

From Engine Stopped

State

Start Fuel 1 To Stopping State

Start Fuel 2 To Stopping State

To Running State

Figure A-1. Start Fuel State When Two Start Fuels are Configured

Start Fuel 1 Sub-state

In this state the actuator position is set to the Start Fuel 1 position.

The control changes from this state to the Stopping state when any of the
following are true:
 Engine speed is below (Start Speed 1 Threshold – Start Speed Hysteresis)
 The Run Enable switch is not active
 The control is shut down
 The Max Starting Time period has elapsed

Also, the control changes from this state to the Running state when both of the
following are true:
 One start fuel is configured
 Engine speed exceeds the Run Speed Threshold

Also, the control changes from this state to the Start 2 sub-state when both of
the following are true:
 Two start fuels are configured
 Engine Speed has exceeded the Start Speed 2 Threshold

Start Fuel 2 Sub-state

In this state, the actuator position is ramped to the Start Fuel 2 value.

The control changes from this state to the Stopping state when any of the
following are true:
 Engine speed is below (Start Speed 1 Threshold – Start Speed Hysteresis)
 The Run Enable switch is not active
 The control is shut down
 The Max Starting Time period has elapsed

Also, the control changes from this state to the Running state when:
Engine speed exceeds the Run Speed Threshold

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Manual 26246 ProAct ISC
Running State
The running state consists of some or all of the sub-states described below. The
speed setpoint configuration determines which of the following sub-states are
applicable.

From Start Fuel or

Stopping State

Ramping

Running
Rated 1

To Stopping State

Figure A-2. Running State When Configured for Rated Speed Setpoint

From Start Fuel or

Stopping State

Ramping to
Idle

Running Idle

Ramping

Running
Rated 1

To Stopping State

Figure A-3. Running State When Configured for Idle / Rated Speed Setpoint

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ProAct ISC Manual 26246
From Start Fuel or
Stopping State

Ramping

Running Running
Rated 1 Rated 2

To Stopping State

Figure A-4. Running State When Configured for Runtime Select Rated 1 / 2
Speed Setpoint

From Start Fuel or

Stopping State

Ramping

Running Rated 1 or Rated 2 is

Rated 1 or 2 selected at start-up.

To Stopping State

Figure A-5. Running State When Configured for Start-up Select Rated 1 / 2
Speed Setpoint

Ramping to Idle Sub-state

In this state, the speed setpoint is ramped to the Idle setpoint at the Ramp to Idle
Ramp Rate if the Ramp to Idle Ramp Rate is configured to be active. If the Ramp
to Idle Ramp Rate is not configured to be active, the speed setpoint is set
immediately to the Idle Setpoint.

The Ramping to Idle state is only used when the speed setpoint is configured for
Idle / Rated.

100 Woodward
Manual 26246 ProAct ISC
The control changes from this state to the Stopping state if any of the following
are true:
 Engine speed is below the Stop Speed Threshold
 The Run Enable switch is not active
 The control is shutdown

Also, the control changes from this state to the Running Idle sub-state when
both of the following are true:
 The Idle / Rated switch is set to Idle
 The Ramp to Idle Ramp Rate is not configured to be active, or engine speed
has reached the Idle Setpoint

Also, the control changes from this state to the Ramping sub-state when:
The Idle / Rated switch selects the Rated Setpoint.

Running Idle Sub-state

In this state the engine is running at the Idle Setpoint speed. The Running Idle
state is only used when the speed setpoint is configured for Idle / Rated.

The control changes from this state to the Stopping state if any of the following
are true:
 Engine speed is below the Stop Speed Threshold
 The Run Enable switch is not active
 The control is shutdown

The control changes from this state to the Ramping sub-state when:
 The Idle / Rated switch selects the Rated Setpoint

Ramping Sub-state
In this state the engine speed is ramped from one setpoint to another at the
Acceleration Ramp Rate or the Deceleration Ramp Rate, as applicable. If the
setpoint selection changes while ramping (for example, changing the Idle / Rated
input back to Rated while ramping from Rated to Idle), the ramp will change
direction and rate as required to reach the new setpoint value. If, while ramping,
the Raise or Lower discrete inputs become active, the control will exit this state,
and the speed setpoint will be controlled by the Raise / Lower inputs.

The Ramping state is not used if the speed setpoint is configured for Rated.

The control changes from this state to the Stopping state if any of the following
are true:
 Engine speed is below the Stop Speed Threshold
 The Run Enable switch is not active
 The control is shutdown

Also, the control changes from this state to the Running Rated 1, Running
Rated 2, or Running Idle states if either of the following is true:
 The speed setpoint has reached the selected setpoint (or selected setpoint
+ modifier range, if applicable)
 The Raise or Lower discrete input is active

Running Rated 1 Sub-state

In this state, the engine is running at the Rated 1 speed setpoint, or the modified
setpoint if speed modifiers are configured.

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ProAct ISC Manual 26246
The control changes from this state to the Stopping state if any of the following
are true:
 Engine speed is below the Stop Speed Threshold
 The Run Enable switch is not active
 The control is shutdown

Also, the control changes from this state to the Ramping state when:
 A different setpoint is selected

Running Rated 2 Sub-state

In this state, the engine is running at the Rated 2 speed setpoint, or the modified
setpoint if speed modifiers are configured.

The control changes from this state to the Stopping state if any of the following
are true:
 Engine speed is below the Stop Speed Threshold
 The Run Enable switch is not active
 The control is shutdown

Also, the control changes from this state to the Ramping state when:
 A different setpoint is selected

Stopping State
The control will change to the Engine Stopped state if both of the following are
true:
 Engine speed is zero
 The Stop State Delay period has elapsed

The control will change to the Running state if all of the following are true:
 The Run Enable switch is active
 Engine speed is greater than or equal to the Stop Speed Threshold
 The control is not shut down
 The Max Starting Time period has not elapsed

102 Woodward
 ProAct Integrated Speed Control Start Fuel behavior.
250
In this range the speed
controlwillbeactive.

Woodward
225
Manual 26246

Run Speed

Speed(RPM)
200
In this range the Start Fuel
willbeactive.

175

150

125

el 1
t Fu n
Start Speed 2 if Star l l th e
a p
100 ing sm am
p e nd er or the r i ve .
g t

Figure A-6. Start Fuel Diagram

De bi g uel 2 ega
is rt F or n
Sta s iti ve
po
Start Fuel 1 l be ll er.
75 wil
ontro
Sp eedC
w
rwil lfol lo
a to
Start Speed 1 Start Fuel 2 Actu
50

< Color Legend >

ProAct ISC

103
25
Engine Speed.

0 to 100 % Actuator position.

Actuator Ramp Rate.

Actuator Position.
0
 ProAct Integrated Speed Control Speed set point behavior.
2000 Modifier Upper limit
Upp R In this range Raise, Lower
er l im ai se A
i t re cti ve andAnalog willeffectthe
ach
ed . speedsetpointifactivated.
Rated 2 Set point

104
1800 e
ti v
t ac
no Raise, Lower, Analog Rated 2 active.
og But Idle is also Active.
al
ProAct ISC

An

Speed(RPM)
Rated 1 Set point
1600 nd
era
ow ive
e, L Act Ra
i s 2 i
Ra ted Idl e se, Lo
An ,
1400 Ra a lo Ra Rate wer a
ted n
ga 1 . d 1 or d An
Ra c ti Ra al og
ve
i se
Ana , Lo . ted n
log w er a
2 h ot ac
as t
no t nd ch a i ve.
act nge
1200 i ve
. d to

Lower Active.

Idle Set Point

1000
Rated Active Raise Active
Idl
eA
c ti
ve
Modifier Lower limit
800
e . In this range Raise, Lower
c tiv hed
ow er A i t re ac and Analog willhave no

Figure A-7. Speed Setpoint Diagram

L
er l im
Low effecton thespeed setpoint.
600

Idle Active Rated Active

400
< Color Legend >
No speed set point
changes.
Analog Ramp rate used.
200 Run Speed
Raise / Lower Ramp rate
used. In this range the speed
g Accel / Decel Ramp rate
t in controlisdisabled,
ar used.
Manual 26246

Woodward
St StartFuelActive.
Idle Ramp Rate used.
0
Manual 26246 ProAct ISC

Appendix B.
ProAct General Specifications

Power Supply:
Normal Operation 18–32 V
Transient/Starting 8–40 V for 1 minute

Performance:
Steady State Speed Band 0.5 % of rated speed
Position Control Accuracy ±3.5% of full travel

Environmental:
Ambient Operation Temperature –40 to +85 °C (–40 to +185 °F)
Storage Temperature –40 to +125 °C (–40 to +257 °F)
Humidity H2: (Woodward) profile
Mechanical Vibration RV2: US MIL-STD-202F, procedure 214A:
0.1 G² /Hz, 10–2000 Hz, 3 hr/axis, 12.8
Grms
Mechanical Shock US MIL-STD-810C, Method 516.3, 516.4
procedure 1
Ingress Protection IP56 per IEC 60529

Reliability:
Mechanical The B10 life is 60 000 Prime Mover service
hours.
The B10 life prior to a rebuild is 30 000
Prime Mover service hours.
Electrical MTBF of 28 000 hours at 60 °C and the
actuator is operating at 75% of capacity.

Torque output:
Model I Transient 2.6 Nm (23 lb-in)
Model I Continuous 1.3 Nm (11.5 lb-in)
Model II Transient 5.2 Nm (46 lb-in)
Model II Continuous 2.6 Nm (23 lb-in)
Model III Transient 10.4 Nm (92 lb-in)
Model III Continuous 5.2 Nm (46 lb-in)
Model IV Transient 20.8 Nm (184 lb-in)
Model IV Continuous 10.4 Nm (92 lb-in)

Mechanical Travel: 73 to 77 degrees

Transfer Function (Positioner)

The transfer function of the position controller is nominally four lags and a rate
limiter (see Figure B-1 below). The first lag is an input filter is set at 0.020
seconds, with a model-dependent slew rate limit. The second lag is set at 0.0033
seconds. The remaining two lags are scheduled with Inertia Number as shown in
the following tables.

1 1 1 1
demand
position
(0.020)s+1 (0.0033)s+1 (Tau3)s+1 (Tau4)s+1

Rate limiter

Figure B-1. Transfer Function

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ProAct ISC Manual 26246

Size Rate Limiter

(deg/s)
Model II 2285
Model III 1882
Model IV, EHT 941

Table B-1 Rate Limiter Values

Model II Model III Model IV, IV EHT

Tau_3 Tau_4 Inertia Inertia Inertia
Number Number Number
0.0040 0.0050 >= 16 >= 17 >= 17
0.0044 0.0063 < 16 < 17 < 17
0.0053 0.0125 < 12 < 13 < 13
0.0063 0.0250 <7 <8 <8

Table B-2 Transfer Function Parameters

Inertia Settings
Inertia=Base_Inertia*1.25^InertiaNumber
The actuator with no load has inertia = Base_Inertia

Size Base_Inertia
Model II 5.5e-4 Kg-m^2
Model III 6.4e-4 Kg-m^2
Model IV 8.2e-4 Kg-m^2
Model IV EHT 8.2e-4 Kg-m^2

Speed PID Controller

The speed control PID is implemented as a standard (interacting) PID. In this
form the Kp gain is applied to the Iout, and Dout terms, yielding:

1 𝑡 𝑑
𝑀𝑉(𝑡) = 𝐾𝑝 [𝑒(𝑡) + ∫ 𝑒(𝜏)𝑑𝜏 + 𝑇𝑑 𝑒(𝑡)]
𝑇𝑖 0 𝑑𝑡
where
Ti is the integral time
Td is the derivative time

106 Woodward
Manual 26246 ProAct ISC

Revision History

Changes in Revision T—
 Updated Regulatory Compliance section with new EU directive
 New Declaration of Conformity & Declaration of Incorporation

Changes in Revision R—
 Corrected inertia settings (page 106)

Changes in Revision P—
 Updated Electrostatic Discharge Awareness section
 Updated MPU Input Diagnostics section for new firmware
 Expanded General Specifications section (Appendix B)

Changes in Revision N—
 Updated Regulatory Compliance information
 New Declaration of Conformity & Declaration of Incorporation

Changes in Revision M—
 Updated control wiring diagram (Figure 1-4)
 Updated mounting and grounding information (Chapter 2)
 Added warning about Gas Engine Stops
 Updated wire shielding information
 Updated Figure 3-8 for various ProAct models
 Updated Position Error explanation
 Added new Figure 4-1 (Communication Harness Connections)
 Updated Error Delay explanation

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ProAct ISC Manual 26246

Declarations

108 Woodward
Manual 26246 ProAct ISC

Woodward 109
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Please reference publication 26246T.

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