Core Information Extraction of Model 9907-205 (Woodward ProAct™ Hand Held Programmer)
1. Basic Product Positioning and Function
Model 9907-205 is a dedicated Hand Held Programmer designed for the Woodward ProAct™ Digital Speed Control System (Models I and II). Its core function is to interface with the ProAct Digital Speed Control via a serial port, enabling users to adjust control parameters, monitor system status, and perform calibration procedures. It serves as the primary human-machine interface (HMI) for configuring and tuning the ProAct control system, which regulates the speed of engines in mechanical drive or generator set applications.
The programmer is powered directly by the ProAct control system (no external power supply required) and features a backlit, four-line LCD display for clear visibility in various operating environments. It is used exclusively during installation, commissioning, maintenance, and troubleshooting of the ProAct control system, and is disconnected from the control when not in use to prevent unauthorized parameter modifications.
2. Physical and Electrical Characteristics
2.1 Physical Design
Form Factor: Handheld, lightweight design for portability; dimensions are approximately 163 mm (length) × 109 mm (width) × 64 mm (height) (refer to Figure 4-1 in the document).
Display: Four-line, backlit LCD screen (supports low-light visibility) that can simultaneously show two menu items or system parameters for efficient monitoring.
Keypad: Full numeric keypad (0-9) and function keys (arrow keys, SAVE, ID, ESC, etc.) for navigating menus, modifying parameters, and saving settings. Key functions are clearly labeled to simplify operation.
Cable: Equipped with a 1.37 m (54-inch) connecting cable terminated with a 9-pin "D" connector, which plugs into the J1 serial port on the ProAct control box. The cable supports RS-422 communication protocol, allowing for extended cable lengths if needed (compatible with RS-422 extension cables for remote operation).
2.2 Electrical Specifications
Power Supply: Derived from the ProAct control system; no independent power source required. Draws minimal current from the control (compatible with ProAct I’s 8–32 Vdc and ProAct II’s 18–32 Vdc power systems).
Communication Protocol: RS-422 serial communication, ensuring reliable data transmission between the programmer and the ProAct control (resistant to electromagnetic interference, EMI).
Operating Temperature Range: –40 to +70 °C (–40 to +158 °F), matching the environmental tolerance of the ProAct control system for use in harsh industrial settings.
3. Key Functions and Operating Procedures
3.1 Core Functionalities
3.1.1 Menu Navigation and Parameter Adjustment
The programmer accesses seven primary menus of the ProAct control system, each dedicated to specific configuration tasks:
Menu 1 (Dynamics Settings): Adjust gain (A/B/C/D), gain breakpoints, stability, compensation, gain ratio, and window width to optimize engine response and stability.
Menu 2 (Alternate Dynamics Settings): Configure a secondary set of dynamics for scenarios like fuel switching or load changes (e.g., standalone vs. grid-parallel operation for generators).
Menu 3 (Speed Reference Settings): Set rated speed, idle speed, acceleration/deceleration time, raise/lower rates, remote speed reference (4–20 mA), droop, and speed switch thresholds.
Menu 4 (Limiter Settings): Define fuel limits (max fuel, start fuel, transient overfuel), torque limits, and start speed to protect the engine from overfueling or overspeed.
Menu 5 (Monitor Menu): Real-time monitoring of engine speed, speed reference, actuator output, discrete input status (e.g., Run/Stop, Idle/Rated), and fault indicators.
Menu 6 (Configuration Set Points): Critical settings including the number of gear teeth (for speed calculation), dynamics map type (linear/non-linear), and failsafe function enable/disable (requires a configuration key for access).
Menu 0 (Error Menu): View active errors (e.g., actuator feedback faults), logged errors (persists after power cycling), and power-up self-test results (valid result = 49).
3.1.2 Parameter Modification and Saving
Parameter Adjustment: Use turtle up/down keys for fine adjustments and rabbit up/down keys for rapid changes to parameter values. The first letter of the active menu item blinks to indicate selectability.
Saving Changes: Modifications to parameters are temporary until the SAVE key is pressed. If the programmer is disconnected or the ProAct control loses power before saving, changes revert to the previously stored values.
Menu Exit: Press the ESC key to exit the current menu; use the - key to remove inactive menus from the display for clarity.
3.1.3 System Diagnostics and Status Monitoring
Self-Test: Upon power-up (when connected to the ProAct control), the programmer performs a self-test. A blank screen after test completion indicates normal operation; press the ID key to display the ProAct control’s software part number and revision level (critical for technical support).
Error Logging: The black square key clears the error log. Active errors (e.g., MPU signal loss, actuator overcurrent) must be resolved before engine operation; logged errors provide a history for troubleshooting intermittent issues.
Real-Time Monitoring: Menu 5 displays live data such as engine speed (rpm), actuator output (%), auxiliary input voltage (for load sharing), and discrete switch status (e.g., Remote Reference enabled/disabled), enabling users to verify system operation during commissioning.
4. Safety and Usage Precautions
4.1 Electrical Safety
Electrostatic Discharge (ESD) Protection: Before handling the programmer or connecting it to the ProAct control, discharge body static by touching a grounded metal surface. Store the programmer in an antistatic bag when not in use to protect internal components.
Wiring Compatibility: Ensure the programmer’s cable is connected only to the ProAct control’s J1 port (9-pin D-connector). Do not connect to other devices (e.g., computers) to avoid damage.
4.2 Operational Safety
Emergency Shutdown: The programmer does not control emergency shutdowns. Always have access to the engine’s independent overspeed shutdown device (required by safety standards) during testing.
Unauthorized Access: Disconnect the programmer after commissioning to prevent accidental or unauthorized parameter changes. The ProAct control does not store programmer connection status; reconnection requires re-entering menus.
Environmental Limits: Do not use the programmer in explosive atmospheres (e.g., Class I, Division 2) unless the ProAct control is certified for such locations. Avoid exposure to water or condensation to prevent electrical shorts.
4.3 Maintenance and Service
Cable Care: Inspect the connecting cable for damage (e.g., fraying, insulation wear) before each use. Replace damaged cables to ensure reliable communication.
Display Maintenance: Clean the LCD screen with a soft, dry cloth; avoid harsh chemicals that may damage the display coating.
Service Support: If the programmer fails (e.g., no display, unresponsive keys), contact Woodward technical support with the ProAct control’s software revision (from the ID key) and the programmer’s part number (9907-205). Do not disassemble the programmer—repair must be performed by authorized Woodward service facilities.
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