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L-Series Integrated Speed Control

1. 0590 0670 ih b DEN AAG 1 499 1 701 0390 0450 2450 2530 8 H Ke 6 223 6 426 1540 1620 3250 3350 0 991 1 143 8 233 8 509 7720 7780 SK CT amp 10230 1 0290 19 409 19 761 25 985 26 136 e B 8590 8650 TE E 119 21819 21971 26 046 30 099 30 211850 1 1920 Use its Figure 2 3 L Series Cover Types Woodward 11 L Series Integrated Speed Control Manual 26250 D H A j YPE 1 SHAFT TYPE 2 CX FLATS THREADED AXIAL HOLE 2480 1X CRUSS HOLE COVER TYPE 1 PHANTOM INCHES MM COVER TYPE 2 PHANTOM INCHES MM Pee TT a LI LI 2X 0800 0860 8 1210 1370 2 033 2 184 f a T V 7 T 3 074 3 479 1 C yy W A i X l Ay L J 4 24 0 2490 6 274 6 324 3919 6203 15 035 13 761 CUUNTER CLUCK WISE Re INTERNAL STOP Lee a f i 7 L NN S Te N w g 60 2 SECTION X X d COUNTER TRAVEL BETWEEN i CLUCKWISE SP INTERNAL STOPS SAN eN NN A in SAX INTERNAL STOP cLuckwise INTERNAL STOP 60 i2 TRAVEL BETWEEN INTERNAL STOPS OU S MSX08 THREAD Ss GB de sd EE V 3310 MIN g14
2. DC Resistance 6 9 Q 1000 ft 20 C maximum 19 strands 1 0 mm corresponds to 18 AWG individually tinned Data Pair 3 twists foot z ae ar z Power Pair 19 strands 1 5 mm corresponds to 16 AWG individually tinned 3 twists foot Drain Shield Wire 19 strands tinned copper shielding braid or shielding braid and foil Cable type Twisted pair cable 2x2 lines Bend Radius 20 x diameter during installation or 7 x diameter fixed position Signal attenuation 0 13 dB 100 ft 125 kHz maximum 0 25 dB 100 ft 500 kHz maximum 0 40 dB 100 ft 1000 kHz maximum DeviceNet cable is a good example of CAN cable but caution should be used as most DeviceNet cables are not rated for on engine temperatures When using DeviceNet cables only use the Thick or Trunk cable The advantage of Thick cables is the conductor size Larger gauge conductors fare much better in high vibration environments 28 Woodward Manual 26250 L Series Integrated Speed Conirol Below are two example DeviceNet CAN cables that are suitable for on engine use if the wiring area stays below 75 C Other cables may exist Part Number Description Belden 3082A PVC 18 AWG shielded data pair 15 AWG shielded power pair 300V insulation Belden 7896A PVC 18 AWG shielded data pair 16 AWG shielded power pair 600V insulation Lapp Cable 2710 250 Halogen free 18 AWG
3. A user definable discrete input configured as Droop can optionally be used to transfer between droop and isochronous control Woodward 37 L Series Integrated Speed Control Manual 26250 Figure 4 3 5 Droop Example Analog Biasing 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 Setting or for Load Share Sync operation The only difference between these modes is how they affect the speed setpoint The Remote Speed Setpoint will adjust the speed within the define range such that a 0 V input signal corresponds to the Low limit and a 5 V input corresponds to a High Limit setpoint assuming a non inverted input If configured as Load Share Sync a mid voltage input signal will provide no setpoint bias Assuming a non inverted input a min voltage input will give max negative bias and a max input voltage will give a max positive bias The bias range is defined as a user configurable percentage of speed setpoint Remote Speed Setpoint Mode The Remote Speed setpoint input typically operates from 0 to 5 Vdc however it can be configured as a 3 V input A direct or reverse acting remote speed setting can be configured using a normal or inverted input selection Between 0 and 5 Vdc the control determines the speed setpoint based on a straight line between the Low Limit and High Limit speed settings configured see Figure 4 4 WARNING UN
4. Termination resistors must be installed only at the physical ends of the network Terminating other midpoint units can overload the network and stop all communications As a rule no matter how many units are on a network there should never be more than two terminations installed If termination resistors are provided within a node the EMC test should be conducted both using and not using the termination network to validate that both wiring versions provide acceptable results This assumes the termination network can be disabled which is generally true Termination is a simple 121 Q 0 25 W 1 metal film resistor placed between CAN high and CAN low terminals differential termination on or near the two end units CAN Network Construction While there are a number of different ways to physically connect devices on a network the most reliable method for multi drop networks is a daisy chain configuration also called a zero drop length connection A backbone with stubs is also acceptable but will require more attention to wiring for reliable performance In a daisy chain wires are run from device one to device two to device three etc In a backbone with stubs a main trunk line is run between the two devices that are physically farthest apart and then stub lines are run from the intermediate devices to the trunk line Stubs should be kept as short as possible and may never exceed 6 m 20 ft See wiring example below for a
5. 0 RPM Figure 4 9 Runtime Fuel Limit Curve Min Fuel Limiting Curve 5418 2193 software only The Min Fuel Limit curve is a software adjustable five breakpoint curve based on engine speed This function when active limits the fuel closing based on engine speed and the curve settings Take care in setting this function to ensure speed is not forced upward to an unsafe level In addition adequate customer provided overspeed protection is essential The minimum fuel limiter is activated by the level of the remote speed setpoint analog input When this input is above 0 5V for the configured delay time the function is activated and the min limit is applied When the input is below 0 5 V the min limiter function is disabled When this limiter is active limiting the position the L Series can annunciate the event with the discrete output Temperature Sensing The L Series has an on board temperature sensor to monitor board temperatures and protect the unit from overtemperature This temperature is monitored and a fault is annunciated if the set point is exceeded 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
6. Faults are separated into two categories Logged Faults and Current Faults The Current Faults are volatile and reset every time power is applied The Current Faults annunciate faults that are presently active detected All Logged Faults are latched and written to the EEPROM They must be cleared through the Service Tool Faults can be globally configured as either latching or non latching This is a general setting that applies to all faults unless otherwise noted When configured as non latching a Reset is not needed If latching mode is configured a Reset or power cycle is required to clear the fault and resume positioning A Reset command can be accomplished by opening and closing a Run Enable discrete input if configured or using the Service Tool A parameter is available to configure each fault to either an alarm or a shutdown Each fault can also independently be set to change the state of the discrete output The shutdown action performed is fault dependent Some faults are dedicated as alarms or shutdowns and cannot be configured they are identified as such below Each possible fault is described below Watchdog Reset Watchdog Reset is true if a watchdog timer timeout occurred which resulted in a reset of the microprocessor This is a hard coded alarm If detected the control will attempt to continue normal operation This fault is always latching and a reset is required to clear it Brownout Reset Brownout Reset is true
7. Load command This feature can be optionally password protected a Configuration File Editor Ex AEE Help New Configura ion File Editor File Help Open 2a Save Dl ta 2 Save As Engine Timing Speed Open From Control Load To Control Ctri L Properties Close Figure 6 13 Configuration Loading Load Configuration File to Control L Series Service Tool DER AEE Communication Tools Help New Configuration Open Configuration File Open Control Configuration Load Configuration File to Control Exit Figure 6 14 Direct Load of Configuration File The Load Configuration File to Control option under the File menu allows loading a configuration file to a control without opening it Thus a password protected configuration file can be downloaded without entering the password while preserving the configuration s security If the control that is being downloaded to already contains a configuration with password protection enabled for configuration loads that password is still required This option is only available in Service Tool version 2 1 and newer Woodward 91 L Series Integrated Speed Control Manual 26250 Configuration Checks Whenever a configuration is saved or loaded to the control some basic checks are performed This check cannot determine is the values are realistic but it makes sure that values are loaded into the required parameters I
8. Lower Speed etc if a new command from CAN is not received within the configured CAN Fail Timeout a CAN Fault is annunciated Faults are globally configured as either latching or non latching An option is available to latch in the CAN fault to ensure a CAN fault is annunciated over the CAN link when configured as non latching Device Identifier The Device Identifier is a Service Tool configurable parameter allowing multiple L Series controllers on a single CAN link Allowed values for the Device Identifier are from 1 to 127 The configured Device Identifier affects the COB ID of the incoming message COB IDs follow the predefined connection set as defined on p78 of DS301 Heartbeat The L Series heartbeat message is transmitted at the user defined Heartbeat Producer Time set using the Service Tool 48 Woodward Manual 26250 L Series Integrated Speed Conirol Network Management NMT States The NMT state machine is implemented per the DS301 standard When the L Series powers up it will transfer through the Initialization state to the Pre Operational state where it will remain until commanded into the Operational state The following are not supported e Synchronization SYNC object e Node Guarding e Service Data Objects SDOs except for the Identity object Device Type and Error Register e Time Stamp Object e Emergency Object In the Pre Operational State e Module Control Services NMT commands are handled
9. Message size is 4 bytes Manual 26250 Byte Parameter Scaling 1 2 Speed Setpt Bias Low byte first 0 to 100 scaled from 0 to 1FFF hex Operational Commands DO Rated 2 Select Bit1 Droop Enable Bit2 Raise Speed Setpt Bit3 Lower Speed Setpt Bit4 Idle Rated Select Bit5 Alternate Dynamics Select Bit6 Power down Mode Select RunEnable Bit7 Reset Command Bit field 4 spare To use any of the operational commands the function must be configured i e Speed Raise Lower command functionality must be configured before the Speed Setpt Raise or Lower will be accepted over CAN Setting bit 6 of byte 3 to a 1 will result in s shutdown command A shutdown alarm reset command is issued by sending a 1 to bit 7 of byte 3 and then setting it back to 0 Transmitted Messages The transmitted parameters are shown in the table below These parameters are transmitted at a frequency of one per second PDO1 Tx Message size is 8 bytes Unused bytes will be set to FF Byte Parameter Scaling 1 2 Actual Speed Low byte first 0 4000 rpm scaled from 0 to 8000h 0 25 rpm bit Diagnostics 1 BitO Watchdog Reset Bit1 Brownout Reset Bit2 EEPROM Fault Bit3 Position Sensor Fault Bit4 Temperature Sensor Fault Bit5 Supply Voltage Fault Bit6 Discrete Out Relay Fault Bit7 Fails
10. Set the detection time to an acceptable level 110 Woodward Manual 26250 L Series Integrated Speed Conirol Error Flag Description Possible Source Possible Action Governor Low Speed This error is set if the actual speed if lower than the speed setpoint minus a configured limit for longer than the configured time The actuator is not capable of opening the fuel control valve max torque The fuel control valve is jammed or stuck The actuator is set up incorrectly 100 position will not completely open the fuel valve The linkage is moved or disconnected The engine is not responding correctly The fuel supply to the engine is restricted The load on the engine is too high The detection margins are set too low The detection time is set up too short A normal load transient will trigger this error Check the torque needed to open the fuel valve against the available torque Fix or replace valve Run the position setup wizard to set up the actuator correctly 100 will open fuel valve Fix or replace linkage Review the engine troubleshooting manual Open restriction in fuel supply check filters Reduce load on the engine to an acceptable limit for this engine Set the margins to an acceptable level Set the detection time to an acceptable level Max Starting Time The max staring time error will be set if the engine is not above run speed wit
11. Storage Temperature 40 to 125 C 40 to 257 F EMC EN61000 6 2 Immunity for Industrial Environments EN61000 6 4 Emissions for Industrial Environments SAE J1113 21 Radiated Immunity 100 V m SAE J1113 11 Conducted Transient Immunity Pulse 5b Suppressed Load Dump 45 V Humidity US MIL STD 810E Method 507 3 Procedure III Salt Spray US MIL STD 810E Method 509 3 Procedure Shock MS1 40G 11 ms sawtooth Random Vibration Random 0 3 G Hz 10 2000 Hz 22 1 Grms 3 h axis Sine 5 G 2 5 mm peak to peak 5 2000 Hz 3 h axis 90 min dwells 1 octave min Drop SAE J1211 Paragraph 4 8 3 modified Thermal Shock SAE J1455 Paragraph 4 1 3 2 Ingress Protection IP56 per EN60529 Electrical Load Power Connection Electrical Transient 2 J per SAE J1455 Paragraph 4 11 2 2 1 Reliability and Quality Goals The L Series control system has a reliability target of 17 500 hours MTBF It also has a quality goal of less than 25 PPM when measuring out of the box defects This quality goal is a target based on continuous improvement 122 Woodward Manual 26250 L Series Integrated Speed Conirol AUX 1 Analog Input Parameter Value Input Type 0 5 V or 3V DC Input Input Scaling 0 V 0 and 5 V 100 range in 0 5V mode 3V 0 and 3V 100 range in 3V mode Max Input Full Scale 5 V 1 or 3V 1 Min Input 0 1 V 1 of Full Scale or 2 88V 1 of Full Scale Isolation None Transient Protectio
12. lower the speed setpoint The Lower input wiring is defective See overview screen for input position The high low and active open or closed selection for the Raise input is selected incorrectly The Control is not configured for Raise lower operation The Raise input is also active and the analog Raise Lower is configured The control is in analog mode Check wiring Set up the correct input modes Configure the Control for Raise Lower operation or raise lower and analog if that is the desired operational mode Set the lower input to the correct state The engine will not lower the speed setpoint 108 Woodward Manual 26250 L Series Integrated Speed Conirol Problem Possible Cause Suggested Tesi Correction Engine unstable Improperly tuned speed or position PID dynamics Using Service Tool tune the position dynamics In most cases the default dynamics are appropriate Using Service Tool tune the speed dynamics Intermittent or incorrect speed signal Verify speed signal shielding recommendations chapter 3 have been followed Verify speed input is wired correctly Ignition and MPU cannot be wired simultaneously Dual dynamics discrete input shorted or open Disconnect starter motor solenoid Activate application Check for correct voltage level between dual dynamics AUX pin and ground pin for known application mode Poor frequency control I
13. osla a gl Overview Setpaint Control Modifiers Fuel Limiting Dynamics Discrete UO Alarm Shutdown Security File Help Apply security to V Read Configuration Required to activate security MV Configuration Load M Allow unsecured tuning of speed input and speed settings Allow unsecured tuning of under torque fuel limiter settings MV Speed Dynamics Edit V Position PID Edit Set Password Figure 6 10 Configuration Editor Security Tab Security Configurations All checked features will have the security password enforced prior to allowing the function Unchecked features will not be prompted with a password Read Configuration When checked requires a password before the configuration can be read from the L Series control protects Open From Control execution This is the minimum level of protection and is required in order to use any other security option Configuration Load When checked requires a password before a configuration can be loaded into the L Series control protects Load to Control execution Woodward 89 L Series Integrated Speed Control Manual 26250 Allow unsecured tuning of speed input and speed settings When checked allows password free access to speed and speed setpoint adjustments from the Edit Speed Settings menu item To use this feature the Configuration Load security option must be selected Allow unsecured tuning of under torque fuel limiter settings 541
14. xj File Communication Tools Help Control Mode Stopping Speed Setpoint 2179 8 rpm Position Setpoint 00 Actual Speed 2179 8 rpm Actual Position 0 2 Overview Alarm Internal Shutdowns Simulated 10 Identification x Overspeed x Governing Error High Si Maximum Start Time Timeout Si Governing Error Low Loss of Speed Input gt 09 Run Enable Temperature Sensor Failed S supply Voltage Fault Si Relay Fault Si Over Temperature 5 Position Error Reset Alarms and Shutdowns Reset Logged Alarms and Shutdowns Connected 7 Alarm x Shutdown Figure 5 5 Service Tool Shutdowns Tab L Series Service Tool O xj File Communication Tools Help Control Mode Stopping Speed Setpoint 2179 8 rpm Position Setpoint 00 Actual Speed 2179 8 rpm Actual Position 02 Overview Alarms Shutdowns Simulated 10 Identification gt EE Prom Failed x Position Sensor Failed Reset Alarms and Shutdowns Reset Logged Alarms and Shutdowns Connected 7 Alarm x Shutdown Figure 5 6 Service Tool Internal Shutdowns Tab Woodward 63 L Series Integrated Speed Control Simulated I O Screen While communicating to the service tool Aux 3 and Aux 4 inputs are not functional since these input pins are used for both Input analog or discrete and for serial communications This screen is provided to facilitate operational testing while con
15. 10mA MAX LOW SIDE DRIVE OUTPUT DESIGNED TO DRIVE A RELAY LAMP OR OTHER STATUS INDICATOR MAXIMUM CURRENT ALLOWED THROUGH THE COIL OR LAMP IS 500mA MAXIMUM VOLTAGE ALLOWED AT THIS TERMINAL IS 32VDC Figure 3 1a Typical L Series Speed Control Application Wiring Woodward 17 L Series Integrated Speed Control Manual 26250 connector key connector oe key Or iC Ou 2 Or 3C Q9 4 Os 5 O7 6 C Connector Pinout as Viewed Looking Into L Series Control O O QO A Figure 3 1b L Series Speed Control Connector Pin Arrangement Connector Pin Description Comment 1 12V 24 Vdc Input Power Supply power 2 TPS Signal Output Direct position feedback output indication 3 PWM AUX Ground for AUX inputs 4 RS 232 transmit CAN H Non CAN unit combination Aux 3 input and service tool input Aux Input 3 CAN unit combination CAN HI and service tool input 5 Input Power Ground Ground for the 12 V 24 V input power 6 RS 232 receive CAN L Non CAN unit combination Aux 4 input and service tool input Aux Input 4 CAN unit combination CAN LO and service tool input 7 5 V Out Power for external sensors 10 mA max 8 Aux Input 1 Aux 1 input 9 Relay Driver Output Status fault detection output 10 Aux Input 2 Aux 2 input 11 MPU MPU speed signal input 12 Ignition Input Ignition speed signal input Description of Electrical UO Representative
16. 435 S as 348 3 5 SHAFT CROSS HOLE d FLATS RELATIVE TO SE Een UNTIN fac z RELATIVE TO THE CLOCKWISE THE MOUNTING HOLE 62 04 MOUNTING HOLE i 03 11 13 STOP Figure 2 4a L Series Shaft Types 12 Woodward Manual 26250 SHAFT TYPE 3 L Series Integrated Speed Conirol 9 3095 1X CROSS HOLE 6 2480 1X CROSS HOLE COVER TYPE 1 PHANTOM 7 INCHES MM CUVER TYPE PHANTOM 7 INCHES MM ai San T E Me ie IN 8 L UL ki 22 Il III vi EE IL TI h v f 1x SR i i C 4 H 3090 3100 i 7 849 7 874 E L 6119 6405 15543 16 269 H 2470 2490 6 274 6 324 L14119 1 4405 35 863 36 589 COUNTER CLOCKWISE INTERNAL STOP d SECTION ef SN 0925 0935 5 2 350 2 374 N lt BI L He HE TRAVEL BETWEEN a e ah INTERNAL STOPS s Dirt A j SHAFT CROSS HOLE L y RELATIVE TO THE Re MOUNTING HOLE E ay j A 97 8 3 5 sc SE Ge p COUNTER CLOCKWISE EEN STOP 60 t2 Gage INTERNA SE SHAE T CROSS HOLE SA pe e E RELATIVE TO THE 262 048 P emer MOUNTING HOLE INTERNAL STOPS aua Figure 2 4b L Series Shaft Types Woodward 13 L Series Integrated Speed Control Manual 26250 SHAFT TYPE 5 SHAFT TYPE 6 9 2480 1X CROSS HULE 0 2480 2X CRUSS HOLE COVER TYPE 1 PHANTOM INCHES MM COVER TYPE 1 P
17. 7 1 Service Tool Speed Dvpnamice eee eee ete reteset eaeeeeeees 96 Figure 7 2a Edit Configuration Settings Menu 5418 2193 software only 97 Figure 7 2b Speed Input Window 5418 1680 and 2226 software versions 97 Figure 7 2c Configuration Settings Window 5418 2193 software only 98 Figure 7 3 Service Tool PID Tuning Window ec eee ete ee eee tees 99 Figure 7 4 Service Tool PID Tuning Properties Window cee 99 Figure 7 5 Service Tool Manual Position Calibration selection 000010 100 Figure 7 6 Service Tool Verify Position Calibration 0 eee 101 Figure 7 7 Service Tool Manual Position Calibration ee 102 Figure 7 8 Service Tool Manual Position Calibration Settings ee 103 Figure 7 9 Service Tool Auto Position Calibration eee 104 Figure B 1 Bode Plot of L Series Response eee ee eee tener eee eeeeeee 126 iv Woodward Manual 26250 L Series Integrated Speed Conirol Regulatory Compliance European Compliance for CE Marking These listings are limited only to those units bearing the CE Marking EMC Directive Declared to 89 336 EEC COUNCIL DIRECTIVE of 03 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility These listings are limited only to those units bearing the ATEX markings as well as the CE Mark ATEX Potentially Declared to 94 9 EC COUNCIL DIRECTIVE of 23 March 1994 Explosive on the approximation
18. DT04 1ePA ITEM REC OPTIONAL aao iai NATING CONNECTOR SESCH DT06 12SA a SECONDARY LOCK RIESS HES E SOCKETS 0462 201 16141 0462 201 16141 ee uai WITHIN 16 INCHES FROM CONNECTOR NOTE IN THE EVENT A WIRE IS NOT USED FOR EACH OF THE 12 PINS ON THE CONTROL A DEUTSCH 114017 PLUG MUST BE USED IN PLACE 3075 7811 1 BW UF EACH MISSING WIRE TO ENVIRONMENTALLY SEAL THE CONTROL CONNECTOR CENTER E Du i T eh 8 1 f fio o o o o Fy E o i 9005 22 873 1 TAH Te S 2 5400 64 516 il MAXIMUM mA t l UL a l Bi 3700 193980 Li E ii ra SEE 17100 143 434 1 E NOTE 26P 9A5 ee CONNECTOR CENTER SE NES 262 045 03 11 13 8500 2159 1 L 9600 24 384 GROUND JUNCTION GROUND JUNCTION Figure 2 2 L Series Outline Drawing 10 Woodward Manual 26250 L Series Integrated Speed Control COUVER TYPE 1 CUVER TYPE d INTERNAL LIP SEAI See EXTERNAL SPRING LOADED LIP SEAI SHAFT TYPE 1 PHANTOM INCHES MM SHAFT TYPE 1 PHANTOM A INCHES MM f y L WW KA om oooo
19. European Zone 2 Category 3 wiring methods as applicable and in accordance with the authority having jurisdiction Field wiring must be suitable for at least 105 C Connect ground terminal to earth ground The actuator should be protected from exposure to sunlight and rain Woodward v L Series Integrated Speed Control Manual 26250 WARNING 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 Do not clean equipment unless power has been switched off or the area is known to be non hazardous AVERTISSEMENT RISQUE D EXPLOSION Ne pas raccorder ni d brancher tant que l installation est sous tension sauf en cas l ambiance est d cid ment non dangereuse La substitution de composants peut rendre ce mat riel inacceptable pour les emplacements de Classe I applications Division 2 ou Zone 2 Electrostatic Discharge Awareness All electronic equipment is static sensitive some components more than others To protect these components from static damage you must take special precautions to minimize or eliminate electrostatic discharges Follow these precautions when working with or near the control 1 Before doing maintenance on the electronic control discharge the static electricity on your body to ground by touching and holding a grounded metal object pi
20. I AF o Thru Cable O7 Ox B amp B Electronics In Line RS232 transceiver Model 232LPTTL connector This module or its equivalent is key required for communication Connector Pinout as Viewed Looking Into L Series Control Figure 5 2b Programming Harness Wiring 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 RS 232 connections on the L Series control 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 will display connected and the Service Tool screen will populate with monitor parameters On CAN versions the Communication Connect command must be issued prior to powering up the L Series Since the same I O pins are used for both Service Tool and CAN communications the only time the Service Tool is enabled is on power up If a Service Tool connect is detected CAN will be disabled and the Service Tool communications will remain active WARNING TRAINED PERSONNEL An unsafe condition could occur with improper use of these software tools Only trained personnel should have access to these tools Woodward 57 L Series Integrated Speed Control Manual 26250 Service Tool Help More help on using Servic
21. IP56 Applicable Standards EN61000 6 4 2001 EMC Part 6 4 Generic Standards Emissions for Industrial Environments EN61000 6 2 2001 EMC Part 6 2 Generic Standards Immunity for Industrial Environments EN60079 15 2003 Electrical apparatus for explosive gas atmospheres Part 15 Type of protection n We the undersigned hereby declare that the equipment specified above conforms to the above Directive s Signature Dan Gear Full Name Engineering Manager Position WGC Fort Collins CO USA Place 2 47 f Of Date 5 09 1183 Rev 10 15 Jul 05 00240 04 EUR 02 06 Declaration of Incorporation Woodward Governor Company 1000 E Drake Road Fort Collins Colorado 80525 United States of America Product L Series Actuator Part Number 6300 1005 and similar The undersigned hereby declares on behalf of Woodward Governor Company of Loveland and Fort Collins Colorado that the above referenced product is in conformity with the following EU Directives as they apply to a component 98 37 EEC Machinery This product is intended to be put into service only upon incorporation into an apparatus system that itself will meet the requirements of the above Directives and bears the CE mark MANUFACTURER Signature James D Rudolph Full Name Engineering Manager Position WGC Fort Collins CO USA Place 24 d la 3 Date 5 09 1182 REV 4 2 May 03 00240 04 EU 02 03 We appreciate yo
22. Input Usage ee gt o s Wy Command 10k Signal to Closed to Activate TS Processor 1000pF 499k ii VvV Reference all analog or discrete inputs to L Series signal ground Pin 3 Figure 3 7 Typical AUX Input Usage Woodward 25 L Series Integrated Speed Control Manual 26250 CAN Communications The L Series can communicate using CANbus protocol or serially using RS 232 CAN is an optional feature that requires additional hardware and a CAN capable processor For protocol details refer to the CAN section in Chapter 4 of this manual RS 232 communications are available on the L Series when used with an external transceiver connected to pins 4 and 6 Serial communications allow for the use of a service and configuration tool with the L Series actuator The simplest way to establish this interface is to use Woodward kit 8923 1061 On CAN capable units both CAN and RS 232 share the same I O pins The L Series performs a check on these pins in power up to determine if the Service Tool is attempting to communicate with the unit If not CAN is initialized and used When finished with the Service Tool functions disconnecting the RS 232 communications and cycling the input power will re establish CAN communications RS 232 Service Tool Connections pin 4 and pin 6 These pins are for serial communication with the L Series actuator An external RS 232 transceiver is necessary to make communications possible with the Woodward L Serie
23. Series service tool A connectivity kit Woodward 8923 1061 can be purchased from Woodward to accomplish this SS BER File Communication Tools Help Control Mode Engine Stopped Speed Setpoint 0 0 rpm Position Setpoint 0 0 Actual Speed 0 0 rpm Actual Position 00 Overview alarms Shutdowns Internal Shutdowns Simulated IO Identification Start Fuel 0 0 es W Fuel Limit 99 6 EEN Speed Setpoint Raw Position Demand 0 0 Target Setpoint Run Enable 0 0 rpm Linearize Droop MPU Speed Input Supply Voltage 21 0 Volt i Electronics Temperature 35 2 C Dynamics Gain 0 036 rpm B Discrete Output Integral 1 20 17sec au f Full Travel Position Setpoint 05 Derivative 0 01 sec G i GEN Full Travel Actual Position 0 5 Gain Window 20 0 rpm e h K i Full Travel Sensor Position 0 0 Gain Ratio 1 00 ratio Connected 7 Alarm X Shutdown Figure 5 1 Example Service Tool Screen Woodward 55 L Series Integrated Speed Control Manual 26250 The following hardware is required to work with the L Series control e PC compatible laptop or desktop Computer with at least one available serial communications port and Windows 95 98 2000 NT Me XP as the operating system e Programming datalink harness as shown in Figure 5 2 In addition to the hardware the following are the distributions of tool software needed to communicate with the control e Woodward pa
24. Status One or more shutdowns on the Shutdowns or Internal Shutdowns screen is active Overview Parameters Screen To monitor the overview parameters go to the Overview page on the main window This screen dynamically populates based on the units configuration If a function is not programmed then it will not appear Woodward 59 L Series Integrated Speed Control Manual 26250 gt Y L Series Service Tool F File Communication Tools Help Control Mode Engine Stopped Speed Setpoint 0 0 rpm Position Setpoint 0 0 Actual Speed 0 0 mm Actual Position 02 Overview alarms Shutdowns Internal Shutdowns Simulated 10 Identification Remote Speed Bias Input Stat Fuel 0 0 0 0 W Fuel Limit 99 6 EE rt Raw Position Demand 0 0 W Raise Li Lower Run Enable W IdleRated W Rated1 Rated2 W Iso Droop MPU Supply Voltage 22 9 Volt Electronics Temperature 27 4 C Gain 0 10 Jrpm g Discrete Output Li Alt Dyn Inteoral abe faa Full Travel Position Setpoint 0 5 gek e E Full Travel Actual ee oos Gain Window 10 0 rpm SC Full Travel Sensor Position 3 5 Gain Ratio 1 19 ratio Connected ER Alarm Shutdown Figure 5 3a Service Tool Overview Tab L Series Service Tool File Communication Tools Help Control Mode Engine Stopped Speed Setpoint 0 0 rpm Position Setpoint 0 0 o Actual Speed 0 0 r
25. Threshold in 8 rpm increments Start Fuel 2 Specifies the maximum permitted 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 0 235 200 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 it will be stopped after a reasonable amount of time Allowed values 0 400 s Run Speed Threshold Specifies the speed at which the Governor State changes from Start Fuel to running Typical value is 90 of the lowest speed reference If the engine speed is above the Run Speed Threshold the control will switch to one of the running states and start using the speed control to drive the actuator position demand Allowed values Must be greater than Stop Speed Threshold and less than 4000 in 8 rpm increments 74 Woodward Manual 26250 L Series Integrated Speed Conirol Engine Stoppin
26. Tool The Service Tool is a Windows based software tool used to configure monitor adjust and troubleshoot a L Series speed control system It runs on a personal computer and communicates with the L Series speed control through a serial connection The L Series Service Tool includes optional password protection to provide security against tampering The speed sensor input contains a software configurable filter that minimizes the effects of firing torsionals that occur normally in reciprocating engines This filter ensures the actuator will 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 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 states based on pre defined alarm or status conditions The control also provides one 0 5 V analog output which provides a position feedback indication This analog output may be used with an analog meter recorder or as input to a computer The control provides a communications port which can b
27. 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 there This will help with diesel pump application or throttle application where it is important to keep the actuator at the closed position if the engine is stopped Allowed values 0 100 Error Detection Settings Governing Error Low Range Maximum error setting to trigger 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 0 400 s Governing Error High Range Maximum error setting to trigger 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 0 400 s Woodward 75 L Series Integrated Speed Control Manual 26250 Overspeed Threshold Specifies the speed level that will trigger an overspeed shutdown fault Allowed values 0 4080 rpm but must be greater than Rated Modifiers Tab The modifiers tab provides droop and speed setpoint biasing configuration settings gt Configuration File Editor Configuration5 cfg e liol x File Help oela E gl Overview Setpoint Control Modifiers Fuel Limiting Dynamics Discrete vo Alarm Shutdown Security Droop C Off soc Droop 10 2 of Ra
28. are short circuit protected to ground and power except pins 3 and 5 which are not protected against shorts to battery positive Installation of a fuse on the power ground wire to pin 5 would provide protection to these pins but does not mean a fuse is not needed in the power connection Pin 1 B still needs protection against a short to ground AUX INPUTS at pins 4 6 8 and 10 ground at pin 3 There are four auxiliary inputs on the L Series control all of which are capable of both analog and discrete functions The Aux functions below are mapped to Aux inputs using the Service Tool If desired multiple functions can be mapped to a single Aux input For added flexibility discrete functions can be programmed to be always on or always off as well as open or closed for the selected function Analog inputs can also be inverted direction reversed Although they are very flexible two Aux inputs are shared with the serial communications and will be unavailable if the L Series is connected to the Service Tool However a means of simulating these inputs is provided for test purposes through the Service Tool interface The functions available for AUX input configuration are Isochronous Loadsharing analog input Remote Speed Setpoint analog input MAP Boost Fuel limit analog input Rated 1 Rated 2 50 60 Hz digital input Raise Speed Setpoint digital input Lower Speed Setpoint digital input Isoch Droop digital input Idle Rated d
29. as required Always make sure the fuel delivery device fuel pump or throttle body has a return spring that pulls towards minimum fuel when no power is applied to the control Size the return spring so that the actuator output shaft sees no more than 0 07 N m 0 05 Ib ft of torque at maximum loading conditions 8 Woodward Manual 26250 L Series Integrated Speed Conirol In addition to a return spring always make sure the application includes a secondary overspeed protection device as a backup to the main governor s overspeed detection function CAUTION MAXIMUM ACTUATOR SPEED 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 1100 degrees per second in both increase and decrease fuel directions under normal operating conditions Exceeding the control input voltage requirements may cause a unit shutdown in which the actuator speed may exceed 3500 degrees per second The Mass Moment of Inertia MMOl for the L Series actuators is 1 48 E 5 kg m 1 57E 3 Ib in s External fuel system stops should be used and must be adequate to absorb the actuator MMOI in addition to the linkage inertia without damage 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 T
30. circuitry for the L Series inputs outputs is provided in Figure 3 5 below Power Supply Input 12 Vdc 24 Vdc at pin 1 ground at pin 5 The L Series will handle a voltage range of 10 to 28 Vdc at full specified torque The actuator is functional in the range of 8 to 32 Vdc but accuracy and or torque can be diminished at the extreme ends of this range The power supply terminals are reverse polarity protected and in the case that a reverse polarity condition exists the L Series actuator will not power up and will remain at the minimum stop if attached to a throttle body with an internal return spring Woodward recommends using a 6 A fuse on the power supply line feeding pin 1 of the L Series actuator 18 Woodward EE Manual 26250 L Series Integrated Speed Conirol The supply voltage failure levels are below 6 25 V and above 33 V The unit can be configured to either alarm or shut down upon detection of a supply voltage fault WARNING FUSED INPUT POWER The input power must be fused Failure to fuse the L Series could under exceptional circumstances lead to personal injury damage to the control valve and or explosion Take special care when wiring the L Series control Ee GE EZE 9 o 8 Figure 3 2 Correct and Incorrect Wiring to Power Supply Ground Symbol Conventions Internal Circuit Board Common Used to show equipotentials in electronic circuits normally internal to
31. demand If two Start Fuel positions are used and speed increases above the Start Speed 2 Threshold the control will position the shaft to the Start Fuel 2 position setting Once the engine speed is above the Run Speed Threshold the control will switch from start fuel demand to the fuel demand from the speed control PID At this point the unit is in speed control and will control the engine to the speed setpoint The PID position during starting is tracking the start fuel values providing a bumpless transfer to speed control At this point the speed setpoint increases to the configured or selected setting ldle Rated Rated 1 or Rated 2 If a shutdown fault is detected the control will drive the output to the configured fail direction position Control Features Description As you review the following features keep in mind that most applications will only require a few of the functions to be activated The choices are available to provide maximum flexibility in a single package The user must set up the actuator direction 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 The user can choose all or none of the fuel limiter functions speed setpoint modifiers alarm shutdown functions security and logic functions depending on the application The control I O consists of input power a speed input 4 configurable aux inputs a status outp
32. discrete in An incompatibility between the Speed setpoint and Raise Speed discrete input is detected To use the Speed Setpt Raise Lower the Raise discrete input cannot be Always Off or Always On See the Setpoint and Discrete I O tabs Configured Raise Lower Bias but no Lower discrete in An incompatibility between the Speed setpoint and Lower Speed discrete input is detected To use the Speed Setpt Raise Lower the Lower discrete input cannot be Always Off or Always On See the Setpoint and Discrete I O tabs Configured Analog or Raise Lower Bias but no Raise discrete in An incompatibility between the Speed setpoint and Raise Speed discrete input is detected To use the Speed Setpt Analog or Raise Lower option the Raise discrete input cannot be Always Off or Always On See the Setpoint and Discrete I O tabs Configured Analog or Raise Lower Bias but no Lower discrete in An incompatibility between the Speed setpoint and Lower Speed discrete input is detected To use the Speed Setpt Analog or Raise Lower option the Lower discrete input cannot be Always Off or Always On See the Setpoint and Discrete I O tabs 93 L Series Integrated Speed Control Manual 26250 27 28 29 30 31 32 Rated Speed Setpoint mode selected and Idle Rated Dynamics selected An incompatibility between the Speed setpoint and Speed Dynamics is detected See the Setpoint and Dynamics tabs Rated Speed Setpoint mode selected and Idle Rated Curv
33. identifier and thus the priority of the message is assigned during the initial phase of system design The identifier with the lowest numerical value has the highest priority Any potential bus conflicts are resolved by bit wise arbitration in accordance with the wired and mechanism by which a dominant state logic 0 overwrites a recessive state logic 1 CANopen Overview CANopen is a networking system based on the CAN serial bus CANopen assumes that the device s hardware has a CAN transceiver and CAN controller as specified in ISO 11898 The CANopen specification covers both application layer and communication profile The CANopen profile family specifies standardized communication mechanisms and device functionality It is maintained by an international users and manufacturers group called CAN in Automation CIA The L Series CANopen Data Link is functional when the optional CAN communication link is used and the CAN Protocol is configured for CANopen For details on the CANopen protocol refer to CIA DS301 Version 4 02 L Series CAN Specifics Parameter Format The L Series uses a Little Endian format when handling multiple byte parameters i e a Bias command of 50 is FFOF not 0FFF All parameters shall use this format unless otherwise specified CAN Bit Timing The L Series bit timing is limited to provide a data rate of 250 kbps only CAN Fault Indication When a CAN command is configured i e Bias Raise Speed
34. is 40 to 105 C 40 to 221 F 40 to 70 C 40 to 158 F for CAN version In spark ignited applications make sure the L Series is located away from the ignition coil and that harness wires are not routed next to the spark plug wires As shown in the specifications the L Series control has 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 L Series Actuator with an ITB Typical mounting of a L Series actuator with an ITB is accomplished by fastening the throttle to the inlet and outlet pipes Ensure that the pipes can support the weight of the L Series actuator and the throttle body Output Shaft The L Series actuator has 58 62 of available travel The max fuel direction of this travel is software configurable in the clockwise or counterclockwise direction through the Service Tool 6 Woodward Manual 26250 L Series Integrated Spee
35. materials that will not damage the surface of the unit e at least 100 mm 4 inches of tightly packed industry approved packing material a packing carton with double walls e a strong tape around the outside of the carton for increased strength Woodward 117 L Series Integrated Speed Control Manual 26250 Return Authorization Number When returning equipment to Woodward please telephone and ask for the Customer Service Department 1 800 523 2831 in North America or 1 970 482 5811 They will help expedite the processing of your order through our distributors or local service facility To expedite the repair process contact Woodward in advance to obtain a Return Authorization Number and arrange for issue of a purchase order for the item s to be repaired No work can be started until a purchase order is received NOTE We highly recommend that you make arrangement in advance for return shipments Contact a Woodward customer service representative at 1 800 523 2831 in North America or 1 970 482 5811 for instructions and for a Return Authorization Number Replacement Parts When ordering replacement parts for controls include the following information e the part number s XXXX XXXX that is on the enclosure nameplate e the unit serial number which is also on the nameplate How to Contact Woodward In North America use the following address when shipping or corresponding Woodward Governor Company PO Bo
36. of the laws of the Member States Atmospheres concerning equipment and protective systems intended for use Directive in potentially explosive atmospheres Zone 2 Category 3 Group Il G EEx nA II T3 X 40 C lt Tamb lt 105 C IP56 Special Condition for Safe Use The installer of the L series must take responsibility for meeting Sub Clause 26 3 3 1 of EN60079 15 2003 regarding impact testing The actuator by itself does not meet this requirement and therefore must be sufficiently protected when installed See Chapter 2 Mechanical Installation for more details Other European and International Compliance Compliance with the following European Directives or standards does not qualify this product for application of the CE Marking Machinery Compliant as a component with 98 37 EC COUNCIL Directive DIRECTIVE of 23 July 1998 on the approximation of the laws of the Member States relating to machinery Pressure Equipment Exempt per Article 1 3 10 Directive North American Compliance These listings are limited only to those units bearing the CSA identification CSA CSA Certified for Class Division 2 Groups A B C amp D T3C at 105 C Ambient for use in Canada and the United States Certificate 1380416 This product is certified as a component for use in other equipment The final combination is subject to acceptance by the authority having jurisdiction Wiring must be in accordance with North American Class Division 2 or
37. rate used and the L Series only supports 250 kbps e The Trunk is the length between the two units at the physical ends of the network or the two termination points if the end units have a drop cable e The Cumulative Drop is the added length of all drop wires from the trunk to the devices e The Maximum Drop is the maximum allowed for any 1 drop 26 Woodward Manual 26250 L Series Integrated Speed Conirol The limits below are the maximum allowed by the CAN standard when isolated Shorter lengths in practice are highly recommended in order to maintain a high level of reliability NOTE Since the L Series CAN communications is not isolated a distance of 40 meters should not be exceeded without adding an isolator Baud Rate Trunk Length Cumulative Drop Maximum Drop 250 kbps 250 m 820 ft 78 m 256 ft 6 m 20 ft CAN Network Termination CAN networks must be terminated with a 121 Q 1 differential resistance at each end of the network It is necessary to terminate the network to prevent interference caused by signal reflections Depending on length may CAN networks will not operate at all without the proper termination Generally it is recommended not to build the termination into a node since CAN is intended to be a plug n play type network with RIUP remove and insert under power However no specific restrictions are placed on the inclusion of termination resistors in a node
38. rated speed A user definable discrete input configured as Idle Rated is used to toggle between the two set speeds The 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 set point for engine warm up or cool down cycles The Idle speed setting is independent of the lower limit set point and may be set at a lower speed Idle speed cannot be changed except by adjustment of the software set point The idle speed set point is selected during starting 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 set point from idle to rated The raise and lower commands increase and decrease engine speed based on the raise and lower rate settings 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 The raise and lower commands will not adjust the speed setpoint above the raise limit nor below the lower limit The control ramps the speed setpoint at the raise or lower rate settings Closing both the raise and the lower
39. shielded data pair 15 AWG shielded power pair 300V insulation CAN Shielding Shielded cable is required for industrial applications Only very cost sensitive automotive applications attempt to use unshielded cable for communications Unshielded cables and improperly shielded cables are likely to cause communication problems and unreliable control operation The standard for CAN networks is that each device will have an ac coupled connected through a 0 01 uF capacitor shield connection and a single shield ground location will be provided The ground location does not have to be at a unit connector it can be any convenient place in the system but should be the same ground as used for the system power NOTE The service port is not isolated and is not intended to function while the prime mover is in normal operation The service port is provided for configuration and setup only Ground Junction see Figure 3 10 This grounding junction is provided for joining external ground wires THERE IS NOT AN INTERNAL CONNECTION TO CIRCUIT GROUND Terminal pins 3 and 5 must be used for access to the circuit ground This junction point is completely electrically isolated from the L Series actuator s electronics and is solely for convenience during installation Woodward 29 L Series Integrated Speed Control Manual 26250 YES Other Units On f es CAN Bus ZA Shielded Twisted Pair STP Shield YES Other CANHI Units
40. 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 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 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 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 sett
41. temperature environment causes board temperatures greater than 117 C The limit curve is a linear derate from full current at 117 C down to zero current at 125 C At 125 C an OverTemp fault is annunciated Depending on the current actuator torque and ambient operating temperatures the unit may never reach a reduced level Woodward 45 L Series Integrated Speed Control Manual 26250 Control Modes The Service Tool displays the state of the L Series control the present mode of the unit Options include e Stopping Engine Stopped Powered Down Start Fuel 1 Start Fuel 2 Ramping to Idle Running Idle Ramping Running Rated 1 Running Rated 2 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 and the holding current is applied to the actuator to limit the current This state is only used if the engine is stopped and the run enable discrete input is not active Start Fuel 1 The Start Fuel 1 state is selected if the engine sp
42. the Control has been placed in an Lower temperature by adding Sense Failed temperature inside the control is higher or lower than allowed by the specifications environment that is too hot or too cold The internal temperature sensor is defective This can be determined by checking the temperature of the unit and comparing this to the service tool value of the electronics temperature cooling heat shielding moving the unit etc Increase temperature by adding heat Return unit to Woodward for repair Governor High Speed This error is set if the actual speed if higher than the speed setpoint plus a configured limit for longer than the configured time The actuator is not capable of closing the fuel control valve max torque The fuel control valve is jammed or stuck The actuator is setup incorrectly Zero percent position will not completely close the fuel valve The linkage is moved or disconnected The engine is not responding correctly The detection margins are set too low The detection time is set up too short A normal load transient will trigger this error Check the torque needed to close the fuel valve against the available torque Fix or replace valve Run the position setup wizard to set up the actuator correctly 0 will close fuel valve Fix or replace linkage Check with the engine troubleshooting manual Set the margins to an acceptable level
43. values seen by the L Series driver using the Service Tool and verify that it matches the input signal e Verify that there are no or minimal ac components to the Analog Input signal AC components can be caused by improper shielding e Check the wiring If the inputs are reading 0 or the engineering units correspond to 0 V look for loose connections and disconnected misconnected cables connections e Check the software configuration to ensure that the input is configured properly as the Demand Source Discrete Input If a discrete input is not functioning properly verify the following e Measure the input voltage on the terminal block It should be in the range of 10 28 Vdc e Check the status of the input from the Overview screen of the Service Tool e Check the wiring looking for loose connections or misconnected cables e Verify the input is properly configured CAN Input If the CAN connection is not functioning properly verify the following e Check the values seen by the L Series driver if any using the Service Tool and verify that it matches the sent signal and or received signal e Check the wiring Look for loose connections and disconnected misconnected cables connections Verify 120 Q resistor at ends of transmission lines e Check the software configuration to ensure that the signal is configured properly Device ID fail timeout etc 114 Woodward Manual 26250 L Series Integrated Speed Conirol
44. 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 CAN Communications To use CAN Controller Area Network the L Series version that supports CAN must be purchased CANopen protocol is supported Aux 3 and Aux 4 inputs are not available for other I O options since they are used for CAN communications CAN Basics Data messages transmitted from any node on a CAN bus do not contain addresses of either the transmitting node or of any intended receiving node Instead the content of the message is labeled by an identifier that is unique throughout the network All other nodes on the network receive the message and each performs an acceptance test on the identifier to determine if the message and thus its content is relevant to that particular node If the message is relevant it will be processed otherwise it is ignored The unique identifier also determines the priority of the message The lower the numerical value of the identifier the higher the priority In situations where two or more nodes attempt to trans
45. 0 0 Acceleration Ramp Rate 50 0 rpmisec Deceleration Ramp Rate 50 0 rpmisec Ramp Rate to Idle 100 0 rpmisec Ok Cancel L series Speed Settings Speed Input Speed Setpaints Modifiers Speed Setpoint Low Limit 1500 rpm Speed Setpoint High Limit 1800 rpm OK Cancel Figure 7 2b Speed Input Window 5418 1680 and 2226 software versions Woodward 97 L Series Integrated Speed Control Manual 26250 L series Configuration Settings Speed Input Speed Setpoint Modifiers Fuel Limiting Speed rpm Limit Point 1 304 18 0 Point 2 336 239 Point 3 368 271 Point 4 400 SLL Paint 5 448 32 2 Enable Delay 5 0 Seconds Cancel Figure 7 2c Configuration Settings Window 5418 2193 software only NOTE A Cancel command will prevent the control from saving any changes into permanent non volatile memory however the values are still displayed and used out of RAM To completely cancel any changes power to the control must be cycled Tuning the Position PID The Position PID tuning screen Figure 7 3 is opened by selecting Edit Position PID from the Tools menu The Service Tool can be used to tune the Position PID or to just trend monitor the position PID output In addition the L Series control can be put into a manual control mode from this screen by selecting the Enable Manual Position Tuning checkbox Once in manual mode the position setpoint box is highlig
46. 42 Vrms This function expects engine speed pulses present on pins 11 MPU and 3 MPU The number of flywheel or gear teeth that pass the magnetic pickup for one crankshaft revolution must be programmed for proper speed signal detection L Series O Pin 11 To W Se MPU EE gt Processor MPU Speed 100pF T Sensor Clamped to 5V then compared with 400mV reference L Series Pin 3 MPU K Figure 3 3 MPU Speed Sensing Input IGN ignition Input IGN at pin 12 IGN at pin 3 The L Series control will accept a 1 480 Hz signal from an ignition input of a 2 or 4 cycle 1 20 cylinder engine For standard coil ignition the source may be the negative terminal of the coil primary For distributorless or DIS Direct Ignition System systems the source for the ignition pulses may be two ignition leads from the spark control connected to IGN pin 12 and IGN pin 3 Take care not to reverse IGN on a DIS system or no speed will be sensed This function requires engine speed pulses present on pin 12 IGN of the control The type of engine 2 stroke or 4 stroke and the number of cylinders 1 to 20 must also be programmed NOTE To prevent electrical noise emissions from interfering with the AUX input signals it is recommended that wiring to auxiliary AUX inputs not be routed within 150 mm 6 inches of any high voltage ignition leads 20 Woodward Manual 262
47. 50 L Series Integrated Speed Conirol This is a typical ignition input setup For DIS applications refer to instructions in text above IGNITION Le L Series CONTROL Pin 12 SC To MODULE oil ji SE eK gt Processor TO BATTERY 220pF PTN me 0 04 uF Conditioned clamped and sent to IGNITION COIL processor for frequency counting L Series 7v Pin 3 Ignition Module Ground lt System or Chassis Ground Figure 3 4 Ignition Speed Sensing Input WARNING UNDETECTED FAULTS 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 TPS Output pin 2 referenced to either pin 3 or pin 5 The L Series provides a 0 5 V signal representing actual shaft rotational position where 0 5 V and 4 5 V correspond to full counterclockwise to clockwise rotation respectively This signal is fed directly off the position sensor to ensure no delays are introduced by the processor However this signal is also uncorrected so the difference between this signal and actual position can vary up to 10 over the operating temperature range This gives the end user an indication of throttle position NOTE This output is meant for an approximate indication of shaft position only The unconditioned output accuracy must be considered when using this sig
48. 6250 L Series Integrated Speed Conirol Problem Possible Cause Suggested Tesi Correction The actuator is not opening the fuel control valve during engine cranking The control is configured for the wrong opening direction The Run Enable input is not enabled See overview screen on service tool The control has detected a shutdown situation and has not been reset There is no power supplied to the control The control does not read any speed Speed sensor defect wiring defect or incorrect speed sensor installation The control reads an actual engine speed below the start speed threshold The Start fuel 1 and or 2 setup is incorrectly set Check cw ccw min fuel direction configuration Make sure the run enable input is made active Check wiring Reset the control by cycling power to the control hitting reset on the Service Tool or toggling the run enable switch Check fuse wiring and battery voltage Fix or replace speed sensor fix wiring or install speed sensor correctly according to the speed sensor manual Start speed is set too high Lower start speed threshold Set up the Start Fuel to the correct value for this engine The engine overspeeds on start up An overshoot in speed is caused by an excessive speed setpoint acceleration The overspeed trip level is configured incorrectly Incorrect speed input configuration Gains not set properly for transients Sta
49. 8 2193 software only When checked allows password free access to Min Fuel Limit Limit settings from the Tools Edit Configuration Settings menu item To use this feature the Configuration Load security Security tab and the Under Torque Limiter Fuel Limiting tab options must be selected Speed Dynamics Edit When checked requires a password before allowing tuning to the speed PID protects Edit Speed Dynamics screen Position PID Edit When checked requires a password before allowing tuning to the position PID protects Edit Position PID screen Position Calibration When checked requires a password before the position calibration mode can be entered protects Manual and Automatic Position Calibration screens L Series Service Tool 3 x Enter a password to enable security for the control and for this configuration Password Verity Figure 6 11 Security Tab Set Password Pop up L Series Service Tool i x Enter a password to enable security for the control and for this configuration A password 5 characters or longer is recommended Password freaeeeee Verify frrr o Figure 6 12 Password Entry Prompt 90 Woodward Manual 26250 L Series Integrated Speed Conirol Loading the Configuration Save Select the File Load to Control option from the menu or Blue Arrow icon on the Configuration Editor to load the changes into the control The L Series speed must be zero prior to allowing a
50. 93 software oh 60 Figure 5 4 Service Tool Alarms Tab 62 Figure 5 5 Service TOOI Shutdowns Tab 63 Figure 5 6 Service Tool Internal Shutdowns Tab 63 Figure 5 7 Service Tool Simulated UO Tab 64 Figure 5 8 Service Tool Identification Tab 65 Figure 6 1 Configuration Selection Options ec eeeeeeeeeeeeeeeeeneeeeeeneeeeeeeaas 67 Figure 6 2 Configuration Editor OVERVIEW TA 68 Figure 6 3 Configuration Editor SETPOINT TAB eessen 71 Figure 6 4 Configuration Editor CONTROL TA 72 Figure 6 5 Configuration Editor Modifiers Tab 76 Figure 6 6a Configuration Editor Fuel Limiting Tab 5418 1680 and 2226 software Versions EE 78 Figure 6 6b Configuration Editor Fuel Limiting Tab 5418 2193 SOMWare ONly ic sis cccieks Maadie inh eae dete ts NEEE EEEE 79 Figure 6 6c Configuration Editor Fuel Limiting Tab 5418 2193 SOMWare D I A EE 79 Figure 6 7 Configuration Editor Dynamics Tab 82 Figure 6 8 Configuration Editor Discrete HO Tab 84 Figure 6 9 Configuration Editor Alarm Shutdown Tab 87 Figure 6 10 Configuration Editor Security Tab 89 Figure 6 11 Security Tab Set Password Pop up 90 Figure 6 12 Password Entry Prompt cccccceeeseeeeeeeeneeeeeeaeeeeeenaeeeeeennaeeeeeeaas 90 Woodward iii L Series Integrated Speed Control Manual 26250 Illustrations and Tables Figure 6 13 Configuration Loadmg 91 Figure 6 14 Direct Load of Configuration File 91 Figure
51. Alarm or Shutdown Conditions If the L Series control has any alarm or shutdown conditions refer to Chapter 4 for details on the exact cause of the condition The Service Tool must be used to determine the cause of any shutdown or alarm condition Discrete Output If the discrete output is not functioning properly verify the following Measure the output voltage on the terminal block It should be in the range of 10 28 Vdc when the output is off false The voltage will be in this range only if all shutdowns are false assuming it is configured as Off for Fault This can be verified through the Service Tool Check the wiring looking for loose connections or disconnected misconnected cables Verify the configuration of the output Service Tool If the service tool is not functioning properly review the installation information in Chapter 5 Verify the following Check the wiring looking for loose connections or disconnected misconnected cables Check that Service Tool is running Verify the Port setting is correct Follow on screen error messages Re install software as needed The latest version of software is available for download from the Woodward web site www woodward com software Woodward 115 L Series Integrated Speed Control Manual 26250 Chapter 9 Service Options Product Service Options NOTE There are no serviceable parts on the L Series The following factory options are available for servicing Wood
52. Aux 4 Rated 1 Rated 2 Selected Speed Open Open Speed 1 Idle Open Closed Speed 1 Idle Closed Open Speed 2 Rated 1 Closed Closed Speed 3 Rated 2 Up to a five speed select can be used if the Raise and Lower commands are configured and used as position selectors When using Raise or Lower selections the control ramps the speed setpoint at the raise or lower rate settings This option may be desirable if another rate is needed 36 Woodward Manual 26250 L Series Integrated Speed Conirol Raise Lower Adjust This feature allows the user to change the speed set point with external discrete inputs If both the raise and lower discrete inputs are closed the lower has priority Lower A user definable discrete input configured as Lower acts directly on the internal speed set point within the L Series control and will progressively decrease the speed set point down to a programmable lower limit at the programmed 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 will remain fixed at the last setting reached the instant the input went low Raise A user definable discrete input configured as Raise acts directly upon the internal speed set point within the L Series control and will progressively increase the speed reference up to a programmable upper limit at the programmed raise rate for as long as the input is in a high st
53. DETECTED FAULTS 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 When the generator breaker is open the analog input is used for synchronizing When the generator breaker is closed this analog input is used for isochronous load sharing within a generator system An isochronous load sharing module synchronizer must be connected to provide the isochronous load sharing synchronizer functions 38 Woodward Manual 26250 L Series Integrated Speed Conirol Figure 4 4 Remote Speed Setpoint The typical Woodward Isochronous Load Sharing Synchronizer analog input operates from 3 to 3 Vdc This voltage input signal biases the speed setpoint directly and is not ramped like the speed setpoint sources however a user configurable max analog rate is available to provide a max adjustment rate A positive voltage input increases the speed setpoint A negative voltage input decreases the speed setpoint At zero voltage input the speed setpoint is held constant The adjustable 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 rom speed setpoint change per volt An SPM A synchronizer typically requires a 0 667 of rated rom speed setpoint chan
54. Determines the runtime fuel limiting mode The selections available will vary with software version and Min Fuel Limit setting when used Runtime Fuel Limiting a max actuator position will be used to limit commanded fuel position Runtime Fuel Limiting with Transients a steady state and a transient fuel limit will be used Runtime Fuel Limiting Curve a speed based curve will be used to determine the fuel limit percentage Boost Fuel Limiting Curve a speed based curve will be used to determine the fuel limit percentage 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 80 Woodward Manual 26250 L Series Integrated Speed Conirol Transient Fuel Limit Time Determines the length of time the Transient Fuel Limit will be applied during a transient Only displayed if the mode is set to Runtime Fuel Limiting with Transients Allowed values 0 400 s Sp
55. ER USE 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 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 CAUTION POSSIBLE DAMAGE TO EQUIPMENT OR PROPERTY CAUTION BATTERY CHARGING 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 CAUTION ELECTROSTATIC DISCHARGE Electronic controls contain static sensitive parts Observe the following precautions to prevent damage to these parts Discharge body static before handling the control with power to the control turned off contact a grounded surface and maintain contact while handling the control Avoid all plastic vinyl and Styrofoam except antistatic versions around printed circuit boards Do not touch the components or conductors on a printed circuit board with your hands or with conductive devices IMPORTANT DEFINITIONS A WARNING indicates a potentially hazardous situation which if not avoided could result in death or serious injury A CAUTION indicates a potentially hazardous situation which if not av
56. HANTOM INCHES MM ep y 0980 1140 A ueg i A A 2 490 2 895 THIS SHAFT 7440 7560 IDENTICAL TO 18 898 19 202 f AFT TYPE 5 l US EXTRA P CRUSS H 0 a UM 2470 249 18819 1 9105 47 801 48 527 SECTION X X g i 0620 0650 A eae ae ai 8 13 3 L631 SN 5 20610 0670 L330 1 701 70 0435 SHAFT CROSS HOLE RELATIVE TO THE EI e MOUNTING HOLE Ae ee ei COUNTER CLOCKWISE 262 049 ee aie INTERNAL STOP pte ares 60 12 TRAVEL BETWEEN I RELATIVE TO OUTER INTERNAL STOPS CROSS HOLE Figure 2 4c L Series Shaft Types 14 Woodward Manual 26250 L Series Integrated Speed Conirol Chapter 3 Electrical Installation SS es Introduction This chapter provides instructions on how to connect the L Series control into a system A wiring pinout of the L Series control as viewed by looking into the control s connector feature is shown in Figure 3 1 Typical connections to external devices are also shown The L Series has an operating voltage range of 10 to 32 Vdc with nominal voltages of 12 or 24 Vdc The power supply is reverse polarity protected and consumes 32 W maximum power at a peak current of 1 A 32 V assuming 4 Q stator resistance at 25 C These assumptions are based on the fact that the software limits the p
57. Mode Displays the state of the L Series control the present mode of the unit Options include Powered Down Engine Stopped Stopping Start Fuel 1 Start Fuel 2 Running Idle Ramping Running Rated 1 Running Rated 2 Ramping to Idle 58 Woodward Manual 26250 L Series Integrated Speed Conirol 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 amp shutdown status Communication Status This section of the status bar shows the status of communication between the service tool and the L Series e Connected The Service Tool is connected to and communicating with the driver e Not Connected The Service Tool is not connected to the driver e Connecting The Service Tool is attempting to connect to the driver This message is displayed when Connect is selected from the Communications menu or when attempting to re establish communication to the driver If the connection is lost it will continuously attempt to re connect Alarm Status One or more alarms on the Alarms screen is active Shutdown
58. O tabs Configured Idle Rated Speed Setpoint but no Idle Rated discrete in An incompatibility between the Speed setpoint mode and Idle Rated discrete input is detected To use the Idle Rated option the Idle Rated discrete input cannot be Always Off See the Setpoint and Discrete I O tabs Configured Rated1 Rated2 Speed Setpoint but no Rated2 discrete in An incompatibility between the Speed setpoint mode and Rated2 discrete input is detected To use the Rated1 Rated2 option the Rated2 discrete input cannot be Always Off See the Setpoint and Discrete I O tabs Configured Idle Rated1 Rated2 Speed Setpoint but no Idle Rated discrete in An incompatibility between the Speed setpoint mode and Rated2 discrete input is detected To use the Idle Rated1 Rated2 option the Rated2 discrete input cannot be Always Off See the Setpoint and Discrete I O tabs Configured Idle Rated1 Rated2 Speed Setpoint but no Rated2 discrete in An incompatibility between the Speed setpoint mode and Rated2 discrete input is detected To use the Idle Rated1 Rated2 option the Rated2 discrete input cannot be Always Off See the Setpoint and Discrete I O tabs Configured Droop Digital Input but no Droop discrete in An incompatibility between the Droop mode and Droop discrete input is detected To use the Droop Discrete input option the Droop discrete input cannot be Always Off or Always On See the Modifiers and Discrete I O tabs Configured Raise Lower Bias but no Raise
59. On CAN Bus Shielded Twisted Pair STP CAN LO NO Other Units On CAN Bus 4 Shielded Twisted Pair STP Shield NO Other Units On Shielded Twisted Pair STP CAN Bus Shield Shield Figure 3 9 CAN Shielding Ground Junction Figure 3 10 Ground Junction Point 30 Woodward Manual 26250 L Series Integrated Speed Conirol Chapter 4 Description of Operation General The L Series Speed Control is an electric actuator with position feedback and an integrated digital speed control 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 60 degrees and is configurable for cw or ccw rotation A manual mode is provided to facilitate setting up the actuator system The speed setpoint can be adjusted by a remote 0 5 Vdc analog input or by discrete inputs such as Idle Rated 50 60 Hz selection 3 Speed or Raise Lower For generator applications isochronous load sharing and synchronizing capability is available by a 3 Vdc analog input in place of the remote 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 L Series Service
60. R AUX1 AUX 1 ANALOG INPUT N 0 5V OR 3V RELAY DRIVER d gt A 5V 12V 24V AUX2 gt AUX 2 DISCRETE INPUT Ar SR AUX 2 ANALOG INPUT MPU 11 7 0 5V E VARIABLE RELUCTANCE ZS SPEED SENSOR MPU 8 IGNITION 12 T Sa A A IGNITION COIL NOTES gt PP gt gt gt Pe P REFERENCE ALL DISCRETE AND ANALOG INPUTS TO PIN 3 SIG GND TO PREVENT ELECTRICAL NOISE EMISSIONS FROM INTERFERING WITH THE AUX INPUT SIGNALS IT IS RECOMMENDED THAT WIRING TO AUXILIARY AUX INPUTS NOT BE ROUTED WITHIN 150 MM 6 INCHES OF ANY HIGH VOLTAGE IGNITION LEADS AUX 3 AND AUX 4 CAN ALSO BE CONFIGURED AS DISCRETE OR ANALOG INPUTS IN A SIMILAR MANNER AS AUX 1 AND AUX 2 BUT ARE NOT FUNCTIONAL WHILE SERIAL COMMUNICATIONS ARE CONNECTED WHEN CAN COMMUNICATIONS IS USED AUX 3 AND 4 ARE NOT CONFIGURABLE ALL SHIELD TIES ARE TO BE NO LONGER THAN 2 BETWEEN THE CABLE AND GROUND IF USING IGNITION SPEED INPUT OPTION CONNECT PIN 12 OF THE L SERIES SPEED CONTROL TO THE NEGATIVE TERMINAL OF THE IGNITION COIL THE IGNITION SYSTEM COMMON MUST BE REFERENCED TO THE L SERIES SPEED CONTROL GROUND PIN 3 OR PIN 5 USE WOODWARD KIT 8923 1061 TO CONNECT TO A COMPUTER FOR USE WITH THE SERVICE TOOL SPEED INPUT IS ACCOMPLISHED BY USING EITHER THE MPU OR THE IGNITION INPUT DO NOT CONNECT WIRES TO BOTH INPUTS SIMULTANEOUSLY WHEN CONFIGURED AS AN ANALOG INPUT THE FULL SCALE RANGE IS 0 5V THE 5V OUTPUT IS PROVIDED FOR POWERING EXTERNAL SENSORS RATED AT
61. Sensing Input 20 Figure 3 4 Ignition Speed Sensing Input 21 Figure 3 5 TPS OUIDUb ecaps eege gedet Sege eee gegen 22 Figure 3 6 Relay Driver Output 23 Figure 3 7 Typical AUX Input Usage cece ee ener eeeeneeeeeeeeeeeeeaeeeeeeneeeeseaas 25 Figure 3 8 CAN System Wiring Example A 28 Figure 3 9 CAN Ghueldmmg rennin aA EEANN EAEE ARANEAE 30 Figure 3 10 Ground Junction Point oseossscssisresieiiinrnnsiii iu ee eeeaeeeeeeeaeeeseenaeeeeeeaas 30 Figure 4 1 Overview of L Series Inputs Outputs ecccceccceeeeeeeeeeeeneeeeeeeeees 33 Figure 4 2 Speed Setpoint Actions and Rates s ssssssseseererrensreeerrnnrrnssrrrrrnnn 34 Figure 4 3 5 Droop Example ssssesessseesseesrrerseestttrrnnstrertrnnntnsntettrnnnn nnne renn 38 Figure 4 4 Remote Speed Getpoinmt renn 39 Figure 4 5 Dual Gain Settings 2 0 0 eee cece eeeeeneeeeeeaeeeeeeaeeeeeeeaeeeseenaeeeeeeaas 41 Figure 4 6 Single Start Fuel Um 42 Figure 4 7 Dual Start Fuel Limiters ssssessssssseennenssnnaseennannannaneennnaanannaaeennaananna 43 Figure 4 8 Boost External Fuel Limit Cume ee cceceeeeeneeeeeenneeeeeeeneeeeeeaas 44 Figure 4 9 Runtime Fuel Limit Curve esssessssssseernasssnnnantennaanannnneennaanannnaneennaananna 45 Figure 5 1 Example Service Tool Green 55 Figure 5 2a Programming Harness Connechons 56 Figure 5 2b Programming Harness VWiimg 57 Figure 5 3a Service Tool Overview Tab 60 Figure 5 3b Service Tool Overview Tab 5418 21
62. U compares this to the speed setpoint and drives the 0 60 degree output shaft to the commanded position based on an internal shaft position sensor The high efficiency torque motor delivers 0 34 N m 0 25 lb ft nominally over 60 travel range to operate fuel or air control devices See the specifications Appendix B for more details There are 4 AUX inputs for I O functions configurable as digital inputs analog inputs or RS 232 Service Tool communications The functions available for AUX input configuration are Isochronous Loadsharing analog input Remote Speed Setpoint analog input MAP Boost Fuel limit analog input Rated 1 Rated 2 50 60 Hz digital input Raise Speed Setpoint digital input Lower Speed Setpoint digital input Isoch Droop digital input Idle Rated digital input Alternate Dynamics digital input Run Enable digital input For status purposes a relay driver output is available on the L Series control which changes state whenever a fault or error condition is experienced by the L Series control If the system so requires the L Series provides a direct position output signal in the form of a dc voltage The throttle position TPS output represents full counterclockwise ccw to clockwise cw rotation of the actuator shaft and thus gives the operator an external position indication after installation and while the unit is operating WARNING EMERGENCY STOP When included with an ITB the actuator depends so
63. W wooDWwarRD Installation and Operation Manual L Series Integrated Speed Control Manual 26250 Revision E WARNING DANGER OF DEATH OR PERSONAL INJURY WARNING FOLLOW INSTRUCTIONS Read this entire manual and all other publications pertaining to the work to be performed before installing operating or servicing this equipment Practice all plant and safety instructions and precautions Failure to follow instructions can cause personal injury and or property damage WARNING OUT OF DATE PUBLICATION This publication may have been revised or updated since this copy was produced To verify that you have the latest revision be sure to check the Woodward website www woodward com pubs current pdf The revision level is shown at the bottom of the front cover after the publication number The latest version of most publications is available at www woodward com publications If your publication is not there please contact your customer service representative to get the latest copy WARNING OVERSPEED PROTECTION 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 WARNING PROP
64. a control system Earth Ground Represents a connection to Earth Ground Chassis Ground Sometimes used as symbol for system ground Normally associated with connection to engine skid or vehicle frame In the case of the L Series it also represents system ground Protective Earth Ground CG _ Normally used as a safety ground in high voltage gt 42V systems Not applicable to L Series Controls Woodward 19 L Series Integrated Speed Control Manual 26250 Flywheel or other MPU speed sensing location The control will continue to function down to a supply voltage of 8 V to withstand a prime mover start from the same battery system however the control will not function completely within specifications During the low voltage the L Series will not meet the transient response times or the max torque output Speed Input The L Series speed input can be either from a magnetic pick up MPU or from ignition system pulses The input must be wired to the appropriate input and must be configured properly using the Service Tool prior to operation See Woodward manual 82510 Magnetic Pickups and Proximity Switches for Electronic Controls for information about MPUs and installation of the pickup unit MPU Input MPU at pin 11 MPU at pin 3 The L Series MPU input will accept speed signals from variable reluctance VR devices in the range of 1 Hz to 12 kHz The acceptable amplitude range is from 1 to
65. afe Fault Bit field Diagnostics 2 BitO Overtemperature Bit1 Position Error Bit2 Overspeed Bit3 Governing Error High Fault Bit4 Governing Error Low Fault Bits Max Start Time Fault Bit6 CAN Fault Bit7 Run Enable Fault Bit field 5 6 Desired Speed Setpt Low byte first 0 4000 rpm scaled from 0 to 8000h 0 25 rpm bit Actual Position 0 to 100 scaled from 0 to FF hex 50 Woodward Manual 26250 L Series Integrated Speed Conirol Control Mode Indication BitO Stopped Bit1 Start Fuel 1 or 2 Bit2 Ramp to Idle 8 Bit3 At Idle Bit field Bit4 Ramping Bit5 Running at Rated 1 Bit6 Running at Rated 2 Bit7 Fuel Limiting Active Fault Detection and Annunciation Faults can be configured to either alarm or shutdown on occurrence An alarm basically does nothing but annunciate the fault A shutdown forces the actuator to a predetermined position regardless of the demanded position The L Series can be programmed to fail in the cw or ccw direction When the shutdown condition no longer exists the L Series is returned to a non shutdown state 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 Faults
66. amics Automatic Actual Speed HU rpm A z DU o Figure 7 5 Service Tool Manual Position Calibration selection Calibration Sequence Overview The following outlines the basic steps required to execute the position calibration Automatic Mode 1 Select Automatic Position Calibration Mode 2 Select cw or ccw Direction 3 L Series automatically rotates in both cw and ccw directions until the stops are detected The values are then captured and stored 4 When completed cycle the power on the L Series 5 It is recommended that a Position Verification be performed to confirm the calibration is correct See Position Verification below Manual 1 Determine the rotational travel limits This can be done by positioning the unit to the minimum and maximum positions and recording the position settings Select Manual Position Calibration Mode Select Direction Enter the pre determined rotational travel limits values When completed cycle the power on the L Series It is recommended that a Position Verification be performed to confirm the calibration is correct See Position Verification below DARN 100 Woodward Manual 26250 L Series Integrated Speed Conirol Position Verification The Position Verification screen Figure 7 6 is opened by selecting Verify Position from the Position Calibration drop down under the Tools menu When the Verify Position screen is entered the control is put into position c
67. analog inputs much the same as Aux 2 When used as a service port the analog and discrete functions will not work Woodward recommends that the service port not be connected during normal use It is intended for system setup and troubleshooting only NOTE To prevent electrical noise emissions from interfering with the AUX input signals it is recommended that wiring to auxiliary AUX inputs not be routed within 150 mm 6 inches of any high voltage ignition leads Communications RS 232 communications are available on the L Series when used with an external transceiver connected to pins 4 and 6 Serial communications allow for the use of a service and configuration tool with the L Series actuator The simplest way to establish this interface is to use Woodward kit 8923 1061 Functions available through this port include tuning monitoring and configuration of the position control Detailed driver status information is also available Any RS 232 wiring must meet the requirements in the EIA RS 232 Standard document The RS 232 standard states that the length of the RS 232 cable between the driver and the PC must be less than 50 ft 15 m with a total capacitance less than 2500 pF The RS 232 data rate is fixed at 19 2 kbps The communication port is non isolated and susceptible to both EMI noise and ground loops related to PC connections and typical industrial environments RS 232 Connections pin 4 and pin 6 These pins are for seria
68. ar linkage design essentially compensates the throttle body so the air fuel flow looks linear from the control s perspective Woodward recommends that linkages use approximately 40 degrees of actuator shaft rotation centered in the full 60 degree range This maximizes the resolution of the actuator control loop making the engine easier to govern Refer to Figure 2 1 for examples of typical linkage designs fuel rack Af actuator fuel rack 40 actuator Rotary to Linear Linkages Linear Relationship corm actuator rotary fuel valve Th rotary fuel valve actuator Rotary to Rotary Linkages Linear Relationship Diesel Gas Gasoline actuator throttle body actuator IR throttle body Rotary to Rotary Linkages Nonlinear Relationship Pull All actuator throttle body A throttle body actuator Rotary to Rotary Linkages Nonlinear Relationship Push Figure 2 1 Linkage Design Examples 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 throttle shaft Once installed 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
69. art Fuel Limiting The Start Fuel Limit SFL is an adjustable limiter on the fuel demand that prevents overfueling during engine starting Two configurable start fuel limiters are available e Single Start Fuel Limit e Dual Start Fuel Limit The single Start Fuel Limit is suitable for most applications With this configuration the fuel demand immediately switches to the adjustable SFL1 Limit setting when the engine is cranking at the adjustable Start1 Speed setting The SFL1 Limit is removed and Runtime Fuel Limiting is activated once the engine accelerates to the Run Speed At the Run Speed the fuel is controlled by the speed control setpoint and ramping functions The Run Speed setting must be set below the speed reached with the SFL1 Limit setting See Figure 4 6 START FUEL LIMIT Runtime Fuel Limit 100 x 75 xe 5 SFL1 Limit E 50 a EN gt L 25 Run Speed 0 0 RPM Starti Speed Figure 4 6 Single Start Fuel Limit The Dual Start Fuel Limit 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 prevent an overspeed shutdown In addition the SFL2 Limit can be set to increase at a controlled rate once the engine is operating at the Start2 Speed setting This can be a useful aid for starting cold engines The Dual start Fuel Limit is appropriate for engines that need this ramping
70. ate assuming the input is configured as active closed When this input goes low the speed reference will remain fixed at the last setting reached the instant the input went low SPEED BIASING Isochronous Droop OFF This is the default speed biasing function if none of the other speed biasing functions are selected This maintains the engine at one speed setting throughout operation regardless of load Droop rthis feature allows for a change in speed set point with a change in load This feature is primarily used when the generator is connected to a utility bus or paralleled with another genset on an isolated bus In this situation the utility will determine the frequency of the alternator 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 speed offset calculated is determined by the user configured droop percentage no load actuator position and full load actuator position parameters Droop is off at start up and is enabled at speeds above Idle
71. atency 6 5 ms Software Routine Nominal Software Execution Rate Position Control Algorithms 1 6 ms Speed Input amp Control Algorithms 6 5 ms Analog Input Logic Serial Port 6 5 ms background task Discrete Inputs 6 5 ms Discrete Output 6 5 ms Diagnostics son A Propbrti naled Friction 25 GE yen a S l egral 25 Derivative ZAN Sh 6 5 ms 180 Ge 10 spar Phase aul men Frequency Figure B 1 Bode Plot of L Series Response 126 Woodward Manual 26250 Manual 26250 L Series Integrated Speed Conirol Woodward 127 DECLARATION OF CONFORMITY According to EN 45014 Manufacturer s Name WOODWARD GOVERNOR COMPANY WGC Industrial Controls Group Manufacturer s Address 1000 E Drake Rd Fort Collins CO USA 80525 Model Name s Number s L Series 8404 xxxx and similar Conformance to Directive s 89 336 EEC COUNCIL DIRECTIVE of 03 May 1989 on the approximation of the laws of the Member States relating to electromagnetic compatibility and all applicable amendments Units marked and conforming to 94 9 EC COUNCIL DIRECTIVE of 23 March 1994 on the ATEX conform to Directive approximation of the laws of the Member States concerning equipment and protective systems intended for use in potentially explosive atmospheres Markings on units conforming to ATEX II 3 G EEx nA II T3X
72. ating temperatures 40 to 105 C 40 to 221 F industrial EMC requirements electrical transients and lower operating voltages 12 24 V NOTE At the time of this writing the CAN version requires a reduced operating ge of 40 to 70 C 40 to 158 F Woodward 1 L Series Integrated Speed Control Manual 26250 Introduction The Woodward L Series combines the L Series electric actuator with integrated speed control software to control the speed of a diesel or gaseous engine The L Series is a microprocessor based control that is incorporated into the actuator creating a single integrated package This eliminates the need for an additional driver box and speed control box The control uses state of the art speed sensing and control algorithms The L Series also performs comprehensive diagnostics for easy troubleshooting It can be configured and tuned using the L Series Service Tool The L Series provides a building block approach to total engine management The modular bi directional actuator design easily attaches to fuel pumps mixers or throttle bodies For information on Woodward throttle body applications refer to manual 26249 ITB and LC 50 Woodward also offers L Series actuator versions for Position Control and Process Control like Air Fuel Ratio control applications Refer to manuals 26237 Position Control or 26251 Process Control The L Series speed control accepts a speed signal ignition or MP
73. ation of the product Woodward 15 L Series Integrated Speed Control Manual 26250 Electrical Connections WARNING 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 Prior to installation refer to the wiring diagrams and the representative I O interfaces schematic in this chapter Also review the hardware I O specifications in Appendix B WARNING INGRESS PROTECTION The control will only meet ingress protection specifications while the Deutsch connector is installed in the unit As such the unit should not be exposed to operating environments unless the mating connector is installed In addition if a wire is not used for each of the 12 pins on the control a Deutsch 114017 plug must be used in place of each missing wire Failure to adhere to these guidelines may result in product failure or decreased life Use 1 to 1 5 mm 16 to 18 AWG stranded copper wire with insulation that meets temperature requirements in the harness design A wiring harness stress relief within 400 mm 16 of the control s connector is recommended Limit all I O and signal lines to less than 30 m 98 ft Also limit input power B B connections to an earth grounded battery or conditioned power interface to less than 10 m 33 ft from the L Series product NOTE A conditioned power i
74. bleshooting 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 WARNING OVERSPEED 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 safet riate WARNING NOISE The L Series is used on prime movers that typically have a high noise level Always use appropriate hearing protection while working around the L Series WARNING WIRING The L Series wiring must be in accordance with North American Class l Division 2 or Zone 2 wiring methods as applicable and in accordance with the authority having jurisdiction Woodward 105 L Series Integrated Speed Control Manual 26250 General System Troubleshooting Guide The following is a general troubleshooting guide for areas to check which may present potential difficulties By making these checks appropriate to your engine turbine before contacting Woodward for technical assistance your system problems can be more quickly and accurately assessed Is the wiring correct Is the direction of the stroke correct Does the valve travel its f
75. ce 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 64 rpm to detect engine cranking Allowed values 16 4000 in 8 rpm increments but must be less than Start Speed 2 Threshold if used and less than the Stop Speed Threshold Woodward 73 L Series Integrated Speed Control Manual 26250 Start Speed Hysteresis is provided for the start speed threshold to ensure that a normal amount of variance in engine speed while in the Start Fuel State does not cause the control to enter the Stopping state After the control has reached the Start Fuel state it will go to the Stopping state if engine speed drops below the Start Speed 1 Threshold Start Speed Hysteresis value Allowed values 50 of Start Speed 1 to Start Speed 1 Threshold in 8 rpm increments Start Fuel 1 Specifies the maximum permitted shaft position when the governor state is Start Fuel 1 Typical value is the same as the full load actuator position Allowed values 0 100 Start Speed 2 Threshold Specifies the speed at which the Governor State changes from start1 to start2 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
76. cel Figure 7 4 Service Tool PID Tuning Properties Window Woodward 99 L Series Integrated Speed Control Manual 26250 Position Calibration and Verification Position calibration is available to map the position command input to the actual rotational travel of the unit It is only used when the full travel of the actuator is constrained or limited such that 0 to 60 degrees of travel is not used For example an application specific position calibration could map 0 100 position command to 10 40 degrees actual rotation There are two methods available to perform a position calibration Automatic or Manual If the application has hard stops that correspond to the actual min max travel then either Auto or Manual methods can be used although auto is easier If hard stops are not available then the auto method will give invalid results and the manual method must be followed The Service Tool can be used to calibrate the control to end user stops physical or soft or to verify the position calibration To get to the Position Calibration screens select the desired function from Position Calibration under the Tools menu selection NOTE Position Calibration is only used when the full travel of the actuator is constrained or limited such that 0 to 60 degrees of travel is not used gt L Series Service Tool File Communication Bt Verify Position Control Mode Speed Setpoint 00 o ER Edit Speed Dyn
77. celeration and Deceleration Rates o Droop Isoch o Biasing Behavior and Rates e Speed Control Setup Parameters o Behavior o Start Speed settings and Rates o Engine Stopping Settings o Speed Error Detection Settings o Dynamics Settings e Fuel Limiting o Behavior o Settings and Rates Discrete Output Settings Discrete Input Settings Fault Settings Security Settings Woodward 3 L Series Integrated Speed Control Manual 26250 Service Tool Software The L Series Service Tool software is a Microsoft Windows based GUI graphic user interface The Service Tool Software is compatible with Windows 95 98 NT 2000 Me XP and gives the OEM the ability to e 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 In addition the Service Tool can be configured to incorporate security to control access to and protect application settings where needed Detailed descriptions of software features and installation are available in Chapters 4 7 4 Woodward Manual 26250 L Series Integrated Speed Conirol Chapter 2 Mechanical Installation ESS eee Introduction This chapter provides instructions on how to mount and connect the L Seri
78. configuration there is no external speed adjustment 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 50 60 Hz Rated 1 Rated 2 Select This feature allows the user to switch the speed set point between a primary and secondary engine rated speed A user definable discrete input configured as Rated1 Rated2 is used to toggle between the two set speeds The input can be configured to select Rated 2 on either opening active open or closing active closed of the contact input This mode can be configured for start up select or runtime select Runtime Select The user can toggle between the two speed settings at any time during operation The transition rate between the two speeds is determined by the configured acceleration and deceleration rates If the setpoint is increasing it will use the acceleration rate If decreasing the deceleration rate is used Start up Select When run speed is reached speed setpoint will ramp to Rated 1 or Rated 2 setpoint depending on the state of the Rated 1 Rated 2 discrete input After run speed is reached the Rated 1 Rated 2 discrete input will have no effect until speed is below the stopping speed Woodward 35 L Series Integrated Speed Control Manual 26250 Idle Rated Select This feature allows the user to toggle the speed set point between an idle and a
79. configured as a shutdown the control will drive to Fail Direction using position control if this fault is detected If configured as an alarm the control will attempt to continue normal operation if this fault is detected If faults are set to non latching this fault will not automatically reset until the control is return to a safe condition determined as the powered down or stopped state Failure levels lt Governing Error Low configured level Persistence Governing Error Low Delay configured value Max Start Timeout A failure to start indication Run speed not attained prior to max start timeout This is a hard coded shutdown If detected the control output will drive to the closed position The control must return to a safe condition determined as the powered down or stopped state prior to resuming operation Failure level and persistence starting time gt configured max start timeout Run Enable Shutdown Run Enable discrete input is opened only active when this input is configured for use This is a hard coded shutdown Minimum Fuel Limiting 5418 2193 software only Indication that the Min Fuel Limit is active Can be configured as an alarm or shutdown If configured as a shutdown the control will drive to Fail Direction using position control if this fault is detected If configured as an alarm the control will attempt to continue normal operation if this fault is detected CAN Fault 5418 2226 software only Ind
80. contacts enables the analog input for remote variable speed setpoint control if configured In Analog Mode the Analog Rate Limit is used Three Speed Select Some refrigeration applications may find it useful to have three engine speeds available a highest speed for quick cool down when warm goods are put into a container a lowest speed to maintain the load s temperature once it has been cooled and an intermediate speed for increased cooling if the container door is opened to move goods in or out Typically the discrete inputs for each of these speeds will come from an automatic thermostat and only one will be high at a time Mobile access platform scissor lift applications may also require three engine speeds which correspond to three basic operating modes static lift transient lift and mobile vehicle travel To provide this feature two user definable discrete inputs must be configured as Idle Rated and Rated1 Rated2 The Idle Rated input has the higher priority if Idle is selected the setpoint will move to the idle speed setting The Rated1 Rated2 input will determine the selected speed when the Idle Rated input is selecting rated During transitions the acceleration and deceleration rates are used Example If the inputs are configured as follows Idle Rated Aux3 active closed and Rated1 Rated2 Aux 4 active closed then the following summarizes the 3 speed selection Aux 3 Idle Rated
81. d The Overspeed Threshold must be set to a level higher than the Rated1 speed setpoint See the Setpoint and Control tabs 7 Overspeed threshold must be greater than rated 2 setpoint A properly set speed configuration is detected The Overspeed Threshold must be set to a level higher than the Rated2 speed setpoint See the Setpoint and Control tabs 8 Rated setpoint must be greater than the idle setpoint A properly set speed configuration is detected The Rated speed setpoint must be set to a level higher than the Idle speed setpoint See the Setpoint and Control tabs 9 Rated 1 setpoint must be greater than the idle setpoint A properly set speed configuration is detected The Rated1 speed setpoint must be set to a level higher than the Idle speed setpoint See the Setpoint tab 10 Rated 2 setpoint must be greater than the idle setpoint A properly set speed configuration is detected The Rated2 speed setpoint must be set to a level higher than the Idle speed setpoint See the Setpoint tab 11 Password must be set when security is enabled To use security a password must be selected See Security tab 12 Configured Run Enable discrete in as Always Ont The Run Enable discrete input cannot be Always Off or the unit will never run See the Discrete I O tab 13 When dynamics 2 is set to rated curve mode dynamics 1 must be in rated curve or idle rated curve mode An incompatibility between the Dynamics modes has been detected To use
82. d Conirol Mounting Orientation While it is not a requirement it is good practice to orient the connector feature on the control in a horizontal or downward orientation to minimize fluid accumulation between the enclosure and the mating connector s gasket Actuator Configuration The L Series actuator utilizes a 2 0 50 8 mm square mounting bolt pattern and is intended to fit within an envelope of 2 618 x 2 618 x 2 540 66 50 x 66 50 x 64 52 mm with the short dimension along the shaft axis Two shaft seal configurations are available an internal lip seal and an external lip seal with spring backup Figure 2 3 In addition six independent output shaft configurations are available Figure 2 4 Consult Woodward applications engineering for the application appropriate seal and shaft configuration Mounting Hardware Use M5 or 10 fasteners torqued to 4 N m 35 Ib in to attach the L Series control to the mounting bracket The bracket and attaching hardware must be designed to hold the weight and to withstand the vibration associated with prime mover mounting Use the appropriate fasteners for securing the mounting bracket to the engine Mechanical Fuel Position Stops Diesel Stops Diesel installations will generally use the fuel system minimum and maximum position stops Diesel engine applications are normally designed to provide the minimum and maximum stops without binding The actuator s stops must not prevent the actuator fr
83. down screens 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 Refer to Chapter 4 for a complete listing and details of all the faults gt gt L Series Service Tool loj xj File Communication Tools Help Control Mode Engine Stopped Speed Setpoint 0 0 rpm Position Setpoint 00 Actual Speed 0 0 rpm Actual Position 01 Overview Alarms Shutdowns Internal Shutdowns Simulated 10 Identification Watchdog Reset 7 Brown Out Reset Reset Alarms and Shutdowns Reset Logged Alarms and Shutdowns Connected 2S Alarm 9 Shutdown Figure 5 4 Service Tool Alarms Tab 62 Woodward Manual 26250 L Series Integrated Speed Conirol Shutdowns and Internal Shutdowns Screens To monitor the shutdown conditions go to the Shutdowns and the Internal Shutdowns pages figures 5 5 and 5 6 on the main window The values displayed on the Shutdowns screen dynamically change with the fault configuration Refer to Chapter 4 for a complete listing and details of all the faults A reset command is available on these screens to clear any current alarms if they are latched on If a fault condition occurred but is no longer present it will remain as a logged fault until cleared The Reset Logged Alarms and Shutdowns command will clear all logged faults A L Series Service Tool 10
84. dward Manual 26250 L Series Integrated Speed Conirol Chapter 7 Setup and Tuning Introduction The L Series is configured using the Service Tool refer to Chapter 5 for Service Tool installation and connection instructions This chapter covers the process of tuning and servicing the control via the L Series Service Tool It is assumed that the control has already been installed on the engine An application requires the following setup steps In many applications these steps have already been performed by the OEM e Configure the L Series control configuration is covered in Chapter 6 e Tune the Speed control loop PID The following optional features are also available e Calibrate the Position Feedback range e Verify Position feedback calibration e Tune the Position control loop PID For most applications the default gains do not need to be changed e Modify Configuration settings speed speed setpoint fuel limiting NOTE Setup and tuning features can be individually password protected for security purposes If security is applied these features will not be accessible without the password NOTE Many applications are delivered pre configured calibrated and tuned For most applications the default gains do not need to be changed Min Position and Fail Direction should be checked WARNING TRAINED PERSONNEL An unsafe condition could occur with improper use of these software tools Only trained personnel should
85. e Loss of Speed Input Run Enable The following conditions are dedicated alarm conditions e Watch Dog Reset e Brown Out Reset WARNING FAULT PROTECTION It is recommended that all faults be configured as shutdowns and selecting Enable Fault Latching this ensures maximum fault protection and prevent 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 as the fault condition goes away the control will be ready for operation The fault log will indicate any faults that have occurred and subsequently cleared Position Error Maximum Sets the magnitude of the position error fault Allowed values 0 100 of stroke Position Error Delay Sets the delay that the position error must persist before indicating a position error fault Allowed values 0 10 s 88 Woodward Manual 26250 L Series Integrated Speed Conirol Security Tab The security tab provides the security configuration settings To use any security the Read Configuration security must be configured for use Once selected the Security Password must be set Figure 6 11 One common password is used for all security selections The password entry is prompted Figure 6 12 whenever a secured function is selected by the user Configuration File Editor Configuration1 cfg loj x
86. e Dynamics selected An incompatibility between the Speed setpoint and Speed Dynamics is detected See the Setpoint and Dynamics tabs Startup Select Rated 1 2 mode selected and Idle Rated Dynamics selected An incompatibility between the Speed setpoint and Speed Dynamics is detected See the Setpoint and Dynamics tabs Startup Select Rated 1 2 mode selected and Idle Rated Curve Dynamics selected An incompatibility between the Speed setpoint and Speed Dynamics is detected See the Setpoint and Dynamics tabs Runtime Select Rated 1 2 Mode selected and Idle Rated Dynamics selected An incompatibility between the Speed setpoint and Speed Dynamics is detected See the Setpoint and Dynamics tabs Runtime Select Rated 1 2 Mode selected and Idle Rated Curve Dynamics selected An incompatibility between the Speed setpoint and Speed Dynamics is detected See the Setpoint and Dynamics tabs Configuration Warnings 1 2 94 Multiple functions configured for Aux1 input This indication is provided to make sure the Aux1 input was configured as expected Multiple functions configured for Aux2 input This indication is provided to make sure the Aux2 input was configured as expected Multiple functions configured for Aux3 Input This indication is provided to make sure the Aux3 input was configured as expected Multiple functions configured for Aux4 input This indication is provided to make sure the Aux4 input was configured as expected Woo
87. e Heartbeat is functional e SDOs those supported are functional In the Operational State e All communication objects are handled including PDOs Process Data Objects In the Stopped State e Module Control Services NMT commands are handled e Heartbeat is functional The following Module Control NMT Zero services are supported e Start Remote Node Stop Remote Node Enter Pre Operational mode Reset Node Reset Communication Requested Messages The software version number parameter filename and serial number messages can be obtained using a request of the Identity Object The Identity Object is accessed via SDO upload at OD Index 0x1018 The Identity Object supports 4 sub indexes e The Vendor ID for Woodward is 0x170 e The Product Code for Speed Control is 0x2 e The Revision Number is defined to be the firmware number plus rev i e firmware 5418 2226 rev NEW would be 541822260 e The Serial Number is a unique identifier set at the factory Received Messages The L Series can receive a bias command and basic operational commands from CAN If an command input is configured as a CAN input a CAN Fault is monitored to ensure adequate message updates The maximum message receive frequency that the L Series can respond to is 6 ms The minimum receive rate prior to an annunciated fault is determined by the CAN Fault Timeout setting in the Service Tool Woodward 49 L Series Integrated Speed Control PDO1 Rx
88. e Tool is available and included with the installation of the Service Tool product Service Tool Help can be accessed from the Service Tool Contents drop down window selection under the Help menu located on the Main Window Software Version Identification The Service Tool software version can found by selecting About under the Help menu The software version is identified as the Software Part Number on the Service Tool screen The Service Tool and Control must be connected to view this information Refer to this version information in any correspondence with Woodward Service Tool Security Various levels of security are available to protect application settings One password is available which provides the ability to inhibit tampering of control settings The individual protection settings include a general password protection on configuration reading from the control configuration loading to the control position calibration position PID tuning and speed PID tuning Monitoring the Driver The Service Tool has six different tab sheets to monitor driver parameters The tab sheet screens include e Overview see Figure 5 3 Alarms see Figure 5 4 Shutdowns see Figure 5 5 Internal Shutdowns see Figure 5 6 Simulated I O see Figure 5 7 Identification see Figure 5 8 Each screen will display the L series control mode actual speed speed setpoint position setpoint and actual position values Control
89. e in rpm s 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 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 used when transferring between rated 1 and rated 2 speeds Raise and lower rates determine how fast speed is increased or decreased by the raise and lower command inputs Max Analog Rate is the maximum rate the speed can be increased or decreased by the remote speed setpoint input The Run Speed setting must be above cranking speed but below the speed attained when running the start fuel limit position The speed control activates at run speed by grabbing the current operating speed as the initial speed setpoint then ramping 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 will pass seamlessly through idle speed to the selected speed setpoint remote rated 1 or rated 2 at the accel rate Speed Setting Options The following section describes the various speed setting modes Single Speed Rated Select lf no speed biasing functions are enabled the engine will run at one set speed With this
90. e of the information from this manual into their application user manuals This manual does not contain instructions for the operation of the complete engine system For engine or plant operating instructions contact the plant equipment manufacturer This version of the manual applies to all L Series Speed Control models with software 5418 1680B 5418 2193 and 5418 2226 or newer The software version can be identified on the Identification tab of the Service Tool How to Use This Manual The following summarizes how to install an L Series speed control into a new or existing system e Unbox and inspect the hardware e Mount and wire the hardware following the procedures and recommendations in Chapters 2 3 e Configure the control using the Service Tool Chapter 6 Not required if pre configured by OEM e Stroke the valve and verify tune dynamics and functionality Chapter 7 Not required if set up by OEM e Troubleshooting guidelines are provided in Chapter 8 e Specifications are provided in Appendix B Intended Applications The L Series speed control is a suitable replacement for mechanical systems that need more flexibility in control strategy like dual dynamics idle rated dynamics and gain curves The L Series control is designed for industrial applications ranging from generators and mechanical drives to pumps and compressors Key environmental characteristics of these applications include extended industrial oper
91. e used as an RS 232 serial interface or a CAN communication connection The RS 232 port is the service port used by the L Series Service Tool to configure and tune the L Series system CAN communications is a future option contact your Woodward representative for availability and options Woodward 31 L Series Integrated Speed Control Manual 26250 System Operation The L Series actuator is ready for operation immediately within 0 25 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 L Series control WARNING EMERGENCY STOP The L Series control should not be used as the primary means of shutting down the engine Starting the Engine A typical engine starting sequence will look like this if no shutdown faults are detected When powered up the L Series control will be in position control at the configured min position If a Run Enable discrete input is configured it must be closed When the starter is engaged the speed will increase above the Start Speed 1 Threshold and the control will position the shaft to the Start Fuel position
92. ed Speed Control Manual 26250 Error Flag Description Possible Source Possible Action Speed Sensor Failed Position Error This diagnostic flag will be set if the speed input pulses have not been detected Indicates demanded position and the actual position are outside the configured limits Damaged loss of speed or wiring Damaged connector Incorrect installation of speed sensor Incorrect configuration of speed sensor Missing pulses on speed gear MPU gap too large MPU signal connection open Ignition signal connection open Incorrect position control dynamics or friction setting Binding or excessive friction in the actuator linkage or stops are set inside the desired range of travel Fix wiring or replace Verify speed signal shielding recommendations chapter 3 have been followed Verify speed input is wired correctly Ignition and MPU cannot be wired simultaneously Fix connector or replace Correct the speed sensor installation See speed sensor installation manual Verify configuration settings Make sure speed gear wheel is not missing any teeth Remove and reinstall MPU per OEM s instructions Rotate engine manually to check for interference Disconnect harness from governor Test for at least 1 Vrms between MPU pin and MPU pin while the flywheel is spinning Disconnect harness from governor Test for bouncing voltage between IGN pin and gr
93. ee speed setpoint control idle and rated 1 and rated 2 Must configure an Idle Rated discrete input and a Rated2 discrete input to provide this function see Discrete I O tab Idle Setpoint Sets the Idle Setpoint Only displayed if Idle is used Allowed values 0 4000 rpm but must be less than Rated Woodward 71 L Series Integrated Speed Control Manual 26250 Rated or Rated 1 Setpoint Sets the Rated Rated 1 Setpoint Allowed values 0 4000 rpm but must be greater than Idle and less than the Overspeed Threshold 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 and less than the Overspeed Threshold Acceleration Ramp Rate Setpoint ramp rate in rpm sec when increasing to a rated setpoint Allowed values 1 1000 rpm s Deceleration Ramp Rate Setpoint ramp rate in rpm sec when decreasing to a rated setpoint Allowed values 1 1000 rpm s Ramp Rate to Idle Setpoint ramp rate in rpm sec when idle speed is selected Only displayed if Idle is used Allowed values 1 1000 rpm s Control Tab The control tab provides engine start and stop configuration settings Configuration File Editor Configuration1 cfg J lol xj File Help Delal 2 Overview Setpoint Control modifiers Fuel Limiting Dynamics Discrete I O Alarm Shutdown Security Engine Starting Settings Start Fuel One amp Tw
94. eed rpm Allowed values Each point 5 must be larger than the previous and less than the next value in increments of 16 rpm Limit Sets the maximum actuator positions 5 based on the current speed Allowed values 0 100 NOTE If the Boost or Runtime fuel limiting curve inputs are changed control power must be cycled before the changes will take effect Boost Fuel Limiting Curve Settings These settings are only displayed if the fuel limiting mode is set to Boost Fuel Limiting Curve Analog Input Configures the boost map analog input to the AUX hardware input A normal input is scaled such that 0 V input provides a 0 boost signal and a 5 V input corresponds to a 100 boost signal An inverted input selection is available to reverse the direction resulting in a 5 V minimum and a 0 V maximum boost input signal If Aux1 input is used the input can be configured as either 0 5 V or 3 V If configured as 3 V replace 0 V by 3 V and 5 V by 3 V in the above discussion Input Type Only displayed if the Input is selected as Aux1 Set to either 0 5 V or 3 V Boost Allowed values Each point 5 must be larger than the previous and less than the next value in increments of 1 2 percent Limit Sets the maximum actuator positions 5 based on the boost analog input Allowed values 0 100 Woodward 81 L Series Integrated Speed Control Manual 26250 Dynamics Tab The dynamics
95. eed is 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 if the engine speed is 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 is only entered if configured to use an Idle Rated speed set point This state is selected if the engine speed is higher than the run speed threshold At the moment this state is entered the speed setpoint is set to the engine speed and then ramped to the idle set point using the ramp to idle ramp rate Running Idle Indicates the speed setpoint is at the configured Idle speed setting To leave this state the rated command must be issued 46 Woodward Manual 26250 L Series Integrated Speed Control 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
96. eed to provide the following information Please write it down here before phoning General Your Name Site Location Phone Number Fax Number Prime Mover Information Engine Turbine Model Number Manufacturer Number of Cylinders if applicable Type of Fuel gas gaseous steam etc Rating Application Control Governor Information Please list all Woodward governors actuators and electronic controls in your system Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number Woodward Part Number and Revision Letter Control Description or Governor Type Serial Number 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 120 Woodward Manual 26250 AUX CRC DFMEA EEPROM EMC GUI IO IGN Isoch ITB L Series MPU OEM PWM rpm RS 232 TPS Woodward L Series Integrated Speed Conirol Appendix A Acronyms Abbreviations auxiliary cyclic redundancy check design failure modes and effects analysis electrically erasable programmable read only memory electro magnetic compatibility graphic user interface inputs outputs ignition speed signal isochronous integrated throttle body Woodward electronic engine governor that contains both a rotary actuator and a control circui
97. enoes 116 Product Service Options cccccceceeeseeeeeceeeeeeeseceeeceeeeeeeeseseccaeaeeeeeeeseeeenaeees 116 Returning Equipment for Repair 117 Replacement Parts 118 How to Contact Woochward nnana nrn nn nenn 118 Engimeernng ET 119 Technical Aesietance A 120 APPENDIX A ACRONYMS ABBREVIATIONSG ccccseseeeeseenseeecenseeeesenseeeees 121 APPENDIX B L SERIES CONTROL SPECIFICATIONS sssssseeeeeeeeeeeeeeenseees 122 DECLARATIONS cctivees cisssaucesivicvensasaccessaveveudssvadeseasvsnedscncstcebaaseseuasentavenavier 128 ii Woodward Manual 26250 L Series Integrated Speed Conirol Illustrations and Tables Figure 2 1 Linkage Design Examples saassseeerreeerrrrssrerrnerirnrsrerrnsrinansennrnedinnnna 8 Figure 2 2 L Series Outline Drawing essseesssssseerneessnnaseennaanannnneennananannaaetnnaananna 10 Figure 2 3 L Series Cover Types 0 eceecceeeeeeeeeeeenneeeeeeneeeeeeaeeeeeenaeeeeeeeneeeeeeaas 11 Figure 2 4a L Series Shaft Types 0 cccccceeceeceeeeeneeeeeeneeeeseeaeeeeeenaeeeeeeeneeeeeeaas 12 Figure 2 4b L Series Shaft Types ssse esssesssrrssseennennsnnanttnnannannnneennaanannnaatennaananna 13 Figure 2 4c L Series Shaft Tvpes 14 Figure 3 1a Typical L Series Speed Control Application Wiring 10000sessee 17 Figure 3 1b L Series Speed Control Connector Pin Arrangement 18 Figure 3 2 Correct and Incorrect Wiring to Power Supply cecceeeesseeeeeenees 19 Figure 3 3 MPU Speed
98. er 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 will be adjusted using both by actuator position and speed Must configure an Idle Rated discrete input to provide this function see Discrete I O tab NOTE 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 19 16 repeats s Derivative Speed control PID derivative term in seconds Allowed values 0 1 66 s 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 0 255 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 15 Woodward 83 L Series Integrated Speed Control Manual 26250 Position Position breakpoints for the gain curve Allowed values Each point 5 must be larger than the previous and less than the next value in increments of 0 4 percent Range 0 100 Gain rpm Sets the
99. eral Installation Operation Notes and Requirements nnssnsssesseeere nenene 5 UNPACKING BEE 6 Mechanical Installation s sisien AE 6 CHAPTER 3 ELECTRICAL INSTALLATION cccccsssssseeeeseseccecseeseneeeseeceneanens 15 INtFOCUCTION Pn eE cece cette A A ees ceaaaaeaeeeeeeesececaeaeeeeeeesetenniseeeeeeeteess 15 Shielded WANG ENEE uge eterna ake dee Deene nie de 15 Description of Electrical UO 18 CHAPTER A DESCRIPTION OF OPERATION ccccseeeeeeeeeeeeeeeeeeeseeeeeeesenneeeeeeees 31 General zarenian a cncacsanecadedne daddvsarcecandasacadiders dd 31 System Opara EE 32 slanting the Engin ET 32 Control Features Description 32 Speed Control Functions ssseseseeneeeeseesntensreetttnrtnsttettttnrnnntaesttntntnnnnenn tenn nn nsten 33 speed Control Dynamit S sererrerrinin sararan E RETE EEE 40 Slant Fuel LIMUN DE 42 Runtime Fuel LmMIN goeroe aE ETEEN 43 Temperature SENSING egeegenegee ee eege EEN eege 45 Current Limiting based on Temperature ssssesssrreseeernasssnnastennaannnnnneennannannaaaeen 45 ele uge Me 46 CAN Communicattons issusisiisendai reia ai AARRE a 47 L Series CAN Specifics AA 48 Fault Detection and Annunciation cccccecceeeeeeeceeeeeeeseeeeeaecaeeeeeeeeeseesnsaneneees 51 Faults oaia a aE A N EEE AE E A 51 CHAPTER 5 SERVICE e e DEE 55 tte let 55 Re edel EEN 55 Getting Started EE 57 Monitoring the Blut 58 CHAPTER 6 CONFIGURATION c0c002cccenceneecccssncececsesnecceressnsacteresne
100. es control into a system Hardware dimensions are provided for mounting the device to a specific application WARNING NOISE Due to typical noise levels in turbine or engine environments hearing protection should be worn when working on or around the L Series WARNING BURN HAZARD The surface of this product can become hot enough or cold enough to be a hazard Use protective gear for product handling in these circumstances Temperature ratings are included in the specification section of this manual CAUTION FIRE PROTECTION Explosion Hazard External fire protection is not provided in the scope of this product It is the responsibility of the user to satisfy any applicable requirements for their system CAUTION WIRING 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 diagrams Figure 3 4 WARNING 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 or Zone applications Woodward General Installation Operation Notes and Requirements WARNING OVERSPEED Use of an independent device for positive shutdown such as a fuel sh
101. f an error is found the Service Tool will not allow the load or save function to be performed until the error is corrected Warnings are displayed for the purpose of configuration confirmation but they will not inhibit the save or load function Configuration Errors 1 Speed Setpoint has not been selected A speed setpoint mode must be configured prior to use See Setpoint tab 2 Speed Input has not been configured The speed settings must be configured prior to use See Speed Input section on Overview tab specifically check the 2 Stroke or 4 Stroke selection 3 Improperly configured speed settings Overspeed setting Number of Cylinders or Stroke The speed settings have been configured beyond the sensing limits of the L Series input capability This only affects speed inputs configured as ignition See the Control for overspeed threshold and Overview for speed settings tabs 4 Overspeed threshold must be greater than idle setpoint A properly set speed configuration is detected The Overspeed Threshold must be set to a level higher than the Idle speed setpoint See the Setpoint and Control tabs 5 Overspeed threshold must be greater than rated setpoint A properly set speed configuration is detected The Overspeed Threshold must be set to a level higher than the Rated speed setpoint See the Setpoint and Control tabs 6 Overspeed threshold must be greater than rated 1 setpoint A properly set speed configuration is detecte
102. function 42 Woodward Manual 26250 L Series Integrated Speed Conirol With this configuration the Dual Start Fuel Limiter works just like two sequential start fuel limiters plus a ramp between them Extra settings Start2 Speed and SFL2 Limit w Ramp provide the second limiter function between the Start1 Speed and Run Speed Once Start1 Speed is reached the limiter ramps the SFL2 Limit setting at the configured ramp rate Setting the rate to its maximum value effectively eliminates the ramp Start2 Speed must be set higher than the Start1 Speed setting The SFL2 Limit can be set lower or higher than the SFL1 Limit setting See Figure 4 7 DUAL START FUEL LIMIT w RAMP SFL2 Limit Runtime SFL1 w Ramp Fuel Limit Limit sec 100 75 50 SFL2 Limit Fuel Demand 25 Start2 Speed Run Speed 0 RPM gt Start1 Speed Figure 4 7 Dual Start Fuel Limiters 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 e Maximum Fuel Limit e Maximum Fuel Limit with Transients e Boost External Fuel Limit Curve e Runtime Speed based Fuel Limit Curve Maximum Fuel Limit The Maximum Fuel Limit setting places a maximum limit on the fuel demand actuator position It is generally adjusted to prevent engine ove
103. function Only displayed if the Raise Lower function is configured Allowed values 1 1000 rpm s Analog Operational Mode Determines how the analog input range will be applied to the speed setpoint Load Share Sync Operation biasing is based on a percentage band around the speed setpoint 10 Remote Speed Setpoint biasing values are set to a specific speed range 1000 to 2000 rpm Woodward 77 L Series Integrated Speed Control Manual 26250 Bias Limit Specifies the maximum desired speed band possible as a percentage of Rated possible 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 NOTE Due to a limitation of the Aux1 analog input the Low Limit may need to be set to a value about 3 below the desired minimum speed setting when using AUX1 Aux 2 4 do not exhibit this limitation Fuel Limiting Tab The fuel limiting tab provides run time and boost fuel limiting configuration settings Y Configuration File Editor Configuration1 cfg 4 m oj x File Help oela e gl Overview Setpaint Control Modifiers Fuel L
104. g Normally On Sets the relay driver to a normally on mode that turns off for any of the faults selected This is the preferred failsafe output configuration Normally Off Sets the relay driver to a normally off mode that turns on for any of the faults selected WARNING OVERSPEED It is recommended that the Relay Output be configured for the failsafe Normally On 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 Any of the selected faults will either turn the output off if configured for Normally On or turn the output on if configured for Normally Off WARNING FAULT PROTECTION lt is recommended that all faults be configured to activate the discrete output this ensures maximum fault annunciation NOTE The selection for Loss of Speed Input is incorrectly shown listed as Position Demand Failed This will be corrected in the next Service Tool release The CAN Fault selection is only available in software version 5418 2226 and the At Minimum Fuel Limit selection is only available in software version 5418 2193 86 Woodward Manual 26250 L Series Integrated Speed Conirol Alarm Shutdown Tab The Alarm Shutdown tab provides alarm and shutdown configuration
105. g 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 4 5 Setting the gain ratio to 1 disables the function Figure 4 5 Dual Gain Settings Woodward 41 L Series Integrated Speed Control Manual 26250 Dual Dynamics The L Series speed control also provides a 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 Two sets of dynamics are useful for engines where operating modes change such as in dual fuel or in island parallel generator applications Delay settings are available to delay switching dynamics when the 2nd Dynamics discrete input changes state St
106. g Settings 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 will not allow the engine to restart Allowed values Must be greater than Start Speed Threshold and less than Run Speed Threshold in 8 rom increments 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 will take the engine to come to a full stop from the Start Speed 1 Threshold Above the Start Speed 1 Threshold the speed signal loss will result in a speed sensor failure and the engine will not restart until the control is reset Allowed values 0 400 s Stopped State Holding Current In the stopped state the control will drive the actuator closed with the Stopped State Holding Current This is
107. gain value 5 based on the position Allowed values 0 0 778 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 Allowed values 0 8 Discrete I O Tab The Discrete UO tab provides discrete input and discrete output configuration settings gt Configuration File Editor Configuration1 cfg File Help NEI 2 Overview Setpoint Control Modifiers Fuel Limiting Dynamics Discrete vo Alarm Shutdown Security Inputs Raise Always Off Rated 2 JAways Of gt Lower Jess Op gt Droop JAwaysOf zl Dual Dynamics AlwaysOf zl Run Enable fAlwaysOf zl Idle Rated Aways Of zl Outputs Relay Output Normally On C Normally Off Off when selection becomes true Watch Dog Reset M Over Temperature Brown Out Reset M Position Error V EE Prom Fail M Overspeed M Position Sensor Failed Governor High Speed M Temperature Sensor Failed V Governor Low Speed M Supply Voltage Fault M Maximum Starting Time V Relay Fault Run Enable Position Demand Failed M CAN Fault Figure 6 8 Configuration Editor Discrete I O Tab 84 Woodward Manual 26250 Input Configurations This section facilitates the mapping of the control functions to the desired Aux input Options include Always Off Aux1 active closed Aux2 active closed Aux3 active closed Aux 4 active closed Aux1 active open Au
108. ge per volt Other load sharing controls may need different settings If configured for Aux1 input it is programmable as either a 0 5 V input or 3 V input Aux 2 4 inputs are limited to 0 5 V signals only The bias percentage is a programmable value When configured as a 0 5 V input 5 V corresponds to the full bias percentage in a positive direction 0 V corresponds to the full bias percentage in a negative direction and 2 5 V corresponds to no bias assuming the input is not configured with the invert option This analog input should be provided by a voltage transmitter via twisted shielded wire pairs When configured as a 3 V input 3 V corresponds to the full bias percentage in a positive direction 3 V corresponds to the full bias percentage in a negative direction assuming the input is not configured with the invert option This analog input will be available to interface with Woodward s standard Load Sharing Module This auxiliary input acts directly on the L Series speed reference and biases it by a programmable amount up to approximately 7 in direct proportion to the 3 0 Vdc signal This input will be active only when the L Series is selected for isochronous operation and should be provided via twisted shielded wire pairs Woodward 39 L Series Integrated Speed Control Manual 26250 Combination Analog Biasing and Raise Lower This feature allows both an analog speed set point and raise lower setpoint command
109. graphical representation In most applications a ground wire is needed between all units on the network The preferred method for isolated ports is to include a separate wire in the CAN cable This keeps the communications and ground reference at the same potential at all times For this reason the recommended cable types below are DeviceNet cables which include an extra wiring pair Non isolated nodes may not have a signal ground available for connection If a signal ground is not available use the alternate wiring scheme of connecting the CAN ground wire from the isolated nodes to the B terminal at a non isolated node this is typically the signal reference for CAN if isolation is not provided Woodward 27 L Series Integrated Speed Control Terminating Resistor Manual 26250 Terminating Resistor N Multiple Node Daisy Chain Drop Line Zero Length Drop Line Short Drop Lines 6 m20 ft Figure 3 8 CAN System Wiring Example CAN Cable Recommendations Use only recommended shielded cabling for a CAN network Correct cable is available from Belden Lapp Cable or other suppliers providing an equivalent cable Here are the cable specifications from the DeviceNet standard a good source for CAN requirements Data pair gt impedance 120 Q 10 at 1 MHz Cable capacitance 12 pF ft at 1 kHz nominal Capacitive unbalance 1200 pF 1000 ft at 1 kHz Propagation delay 1 36 ns ft maximum
110. have access to these tools Tuning the Speed PID The Service Tool can be used to tune the Speed PID or to just trend monitor the speed PID output The Speed PID Dynamics screen Figure 7 1 is opened by selecting Edit Speed Dynamics under the Tools menu Pressing the Properties button pops open the Properties Window From this window the user can adjust the trending window properties including the speed range update rate and display range Woodward 95 L Series Integrated Speed Control Manual 26250 L Series Dynamics x il Dynamics 2 Integral 1 20 1 sec Common Gain 800 ratio of gain curve Derivative IT om sec Gain Window 20 0 rpm Gain Ratio 1 00 Position Rated Gain rpm Idle Gain reng Gaint oo 0 08 Gainz 200 012 Gain 3 40 0 oan Gains s98 0 40 Gains 1000 0 60 4950 0 Speed Setpoint Orpm Range 50 to 5 050 rpm 3950 0 Actual Speed Orpm Range 0 0 to 2100 0 rpm 2950 0 Requested Position 0 0 Range 10 to 130 Actual Position 0 0 Range 0 0 to 100 0 950 0 Properties 50 0 E E E Stop Chart Time scale 1 00 Sec Div Period 10 0 Sec Ok 1950 0 Figure 7 1 Service Tool Speed Dynamics Editing of Configuration Settings If configured a window Figure 7 2 is selectable under that Tools menu that allows editing of various configuration settings The settings in this window are a subset
111. he exception of the sensor type can also be modified from the Edit Speed Settings selection under the Tools menu refer to Chapter 7 Editing of Speed Settings Sensor Type Set to either MPU or Ignition This function requires engine speed pulses present on either the ignition pin input pin 12 or the MPU pin input pin 11 Engine Type Set to either 2 stroke or 4 stroke Number of Cylinders Sets the number of cylinders From the sample table below select the value that corresponds to the number of crankshaft degrees between ignition pulses Allowed values 1 20 68 Woodward Manual 26250 L Series Integrated Speed Conirol Degrees Degrees between between pulses pulses 4 stroke 2 stroke cylinders engines engines 1 720 360 2 360 180 3 240 120 4 180 90 5 144 72 6 120 60 8 90 45 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 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 uneve
112. he link connecting the actuator lever to the fuel control lever must be short and stiff enough to prevent flexing while the engine is running Typically in a linkage system there may be links and levers which are supported by customer supplied bearings Additionally there will typically be a section of the linkage where the mass is supported fully by the actuator output shaft Minimizing the mass the actuator is required to support is essential in that excessive mass or vibration levels may damage the actuator s rotor system and shorten the life of the actuator Woodward 9 L Series Integrated Speed Control Manual 26250 1 MOUNTING HARDWARE TO BE SOCKET HEAD CAP SCREWS 106 1902 24 Mo UR EQUIVALENT NO WASHERS TO BE USED COMMENDED SCREW TORQUE 35 IN LB 4 N M La Tu bal E R BRACKET MOUNT APPLICATION A BRACKET OQUT OF FLATNESS OF 010 0 25 MAXIMUM IS RECOMMENDED 3 FOR CONNECTOR INFORMATION REFER TO CONNECTOR ABLE AND APPROPRIATE WIRING DIAGRAM 4 USE OF INTERNAL ACTUATOR STOPS IN APPLICATION NOT RECOMMENDED TORQUE AGAINST STOPS NOT TO EXCEED 200 IN OZ 2 DIMENSIONS ARE SHOWN IN INCHES MM 6 DETAILS SHOWN HERE ARE COMMON TO ALL ACTUATOR ASSEMBLIES HENCE NEITHER COVERS NOR SHAFTS ARE SHOWN IN THESE VIEWS SEE COVER AND SHAFT DETAILS LSEWHERE IN THIS MANUAL ien os INTEGRATED DEUTSCH CONNECTOR CREF
113. hin a configured amount of time Start fuel is set to low Engine will not reach run speed Low temperature of engine will not start engine at start fuel selected Engine is defective and will not start Set start fuel limit to a level where the engine will reach run speed or lower run speed if a possible Select two start fuels with ramp to ramp to more or less fuel during the engine start Check with the engine troubleshooting manual Overspeed This diagnostic flag will be set if the actual engine speed is higher than the overspeed threshold The overspeed parameter has not been set Factory default is zero rpm Engine dynamics are set up too slow for a sudden load reject The actuator is not capable of closing the fuel control valve max torque The fuel control valve is jammed or stuck The actuator is set up incorrectly Zero percent position will not completely close the fuel valve The linkage is moved or disconnected The engine is not responding correctly Set the correct overspeed value Increase the gains decrease gain window or increase gain ratio Check the torque needed to close the fuel valve against the available torque Fix or replace valve Run the position setup wizard to set up the actuator correctly 0 will close fuel valve Fix or replace linkage Check with the engine troubleshooting manual Woodward 111 L Series Integrat
114. hted and the value displayed is actively positioning the output Use this command to create step changes for the PID and monitor the response using the displayed trend Pressing the Properties button pops open the Properties Window Figure 7 4 From this window the user can adjust the trending window properties including the update rate and display range 98 Woodward Manual 26250 L Series Position PID L Series Integrated Speed Conirol Proportional Gain 118 Integral Gain IT 98 Derivative Gain 392 Friction Io 100 0 80 0 70 0 60 0 50 0 40 0 30 0 20 0 0 0 V Enable Manual Position Tuning Position Setpoint 144 0 Position Setpoint 44 0 Range 0 to 100 Actual Position 440 Range 0 to 100 Properties Stop Chart i Time scale 1 00 Sec Div Period 10 0 Sec Ok Min 0 0 Max 100 0 Figure 7 3 Service Tool PID Tuning Window en Chart Properties Strip Chart Chart Period bh Seconds 1 0 SeciDiv Update Rate fa z Updates per second Background Color jo Window Sweep Cursor M Show sweep cursor Sweep Cursor Color Red d Grid MV Show grid Grid Color IO Light Gray zl Number of X Divisions 10 Number of Y Divisions fio 1 0 SeciDiv Xx Pen Position Setpoint z Pen color m Red Label Position Setpoint Units Min Range 0 10 Div Max Range fi 00 Line Width fi OK Can
115. ication that CAN messages PDO Rx are received at a rate slower than the configured minimum update rate CAN Fail Timeout This only applies to commands configured to be received over CAN Can be configured as an alarm or shutdown If configured as a shutdown the control will drive to Fail Direction using position control if this fault is detected If configured as an alarm the control will attempt to continue normal operation if this fault is detected 54 Woodward Manual 26250 L Series Integrated Speed Conirol Chapter 5 Service Tool Introduction This chapter covers the process of installing and servicing the control via the L Series Service Tool It is assumed that the control has already been installed on the engine NOTE Many applications are delivered pre configured calibrated and tuned These units do not require the use of the Service Tool Description The Service Tool software is used to configure tune and troubleshoot the L Series control This chapter describes installation and use of the Service Tool It identifies the parameters available that can be viewed It also provides detailed information on configuring and setting up the L Series to the customer specific field application The Service Tool software resides on a PC personal computer and communicates to the L Series through connector pins 4 and 6 An external RS 232 transceiver is necessary to make communications possible with the Woodward L
116. ice Tool is running Verify the port setting is correct Check fuse wiring and battery voltage Connect the service tool by using the connect menu Woodward 109 L Series Integrated Speed Control Manual 26250 Problem Possible Cause Suggested Tesi Correction Service Tool not communicating Error message displayed on Old version of Service Tool or file corruption or bad install Re install Service Tool get the latest version from the Woodward web site www woodward com software connect PC when trying to Service Tool will not accept password Cap Lock is on lower case retrieval Password is case sensitive make sure you enter the password correctly using upper and If password is lost contact the OEM for Troubleshooting Diagnostic Fault Flags Error Flag Description Possible Source Possible Action Supply Voltage The power supply voltage Bad or damaged battery Replace battery Failure is higher than the diagnostic limits Defective battery charging system Fix battery charging system The Power supply voltage Incorrect setting of power supply Set correct voltage levels on is lower than the voltage level power supply diagnostic limits Power supply wiring too long or too Make sure wiring is of the thin Control will flag low voltage correct thickness and length during higher power uses according to manual Temperature This error is set if
117. if CPU Voltage drops below 4 2 V but not below 1 V The brownout detect circuit will reset the CPU This is a hard coded alarm If detected the control will attempt to continue normal operation This fault is always latching and a reset is required to clear it Woodward 51 L Series Integrated Speed Control Manual 26250 EEPROM Fail EEPROM Fail indicates failure or corruption of the internal non volatile memory If the CRC is not correct for the EEPROM data this fault will be set true This is a hard coded internal shutdown If detected the control output will go limp This fault is always latching and a reset is required to clear it Position Sense Fail This indicates a failure of the internal Position Sensor This is a hard coded internal shutdown If detected the control output will drive to the Fail Direction using current control Failure levels gt 4 75 V and lt 0 25 V Persistence 650 ms Voltage Sense Fail Indicates an out of range signal on the input power Could indicate input power out of range or a fault in the supply voltage sense circuitry Failure levels gt 33 V and lt 6 25 V Persistence 650 ms Can be configured as an alarm or shutdown If configured as a shutdown the control will drive to Fail Direction using current control if this fault is detected If configured as an alarm the control will internally default to an assumed 32 V power supply voltage decreased torque at lower actual voltages and atte
118. igital input Alternate Dynamics digital input Run Enable digital input Woodward 23 L Series Integrated Speed Control Manual 26250 The Service Tool communicates over RS 232 using Aux inputs 3 and 4 Whenever connected the configured Aux input is bypassed ignored Aux X Input Options Aux1 0 5 V analog 3 V analog discrete input Aux2 0 5 V analog discrete input Aux3 0 5 V analog discrete input service tool RS 232 or CAN Aux4 0 5 V analog discrete input service tool RS 232 or CAN Connecting an auxiliary input pin to battery positive voltage activates it assuming the input is configured for Active Closed Removing battery voltage from an input pin or shorting the pin to ground deactivates the input If not using battery voltage with the auxiliary digital inputs it is recommended that at least 3 V be present on an input pin in order to change its state from inactive to active For AUX2 AUX3 and AUX4 greater than 2 5 Vdc is considered high and less than 0 8 Vdc is considered low For the AUX1 discrete input only the input must exceed 3 V to activate the discrete state AUX3 and AUX4 are also used for digital communications such as RS 232 service tool or CAN if the CAN option was purchased RS 232 and CAN will NOT run simultaneously Figure 3 7 shows the most typical usage of the various auxiliary inputs NOTE Aux inputs 3 and 4 are used as service port connections but can also be used as either discrete or
119. imiter must be carefully set since excessive fuel limiting can degrade the loading response On occasion exhaust temperature or other engine parameters are used for the external fuel limiting function The external fuel limiter is not active below the run speed setting With this mode the Maximum Fuel limit setting is still active EXTERNAL FUEL LIMIT 100 S 75 External Fuel g Limit 5 50 a E H 25 0 External Analog Input Signal Figure 4 8 Boost External Fuel Limit Curve Runtime Fuel Limit Curve Runtime Fuel Limit 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 4 9 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 limiter is not active below the run speed setting 44 Woodward Manual 26250 L Series Integrated Speed Conirol TORQUE FUEL LIMIT Torque Limit Fuel Demand
120. imiting Dynamics Discrete vo Alarm Shutdown Security Fuel Limiting SE C Runtime Fuel Limiting Speed rpm Limit C Runtime Fuel Limiting With Transients Point 1 of 0 0 CG Point 2 208 25 1 C BoostFuel Limiting Curve Point 3 496 49 8 Point 4 3008 74 9 Point 5 4000 100 0 Figure 6 6a Configuration Editor Fuel Limiting Tab 5418 1680 and 2226 software versions 78 Woodward Manual 26250 L Series Integrated Speed Conirol Y Configuration File Editor Configuration1 cfg File Help osla aal gl Overview Setpoint Control Modifiers Fuel Limiting Dynamics Discrete VO Alarm Shutdown Security Min Fuel Limiting C NotUsed Speed rpm Limit 9 Under Torque Limiter Paint 1 1008 10 2 Pointz 1504 en Point 3 2048 70 2 Point 4 2496 80 0 Point 5 3504 100 0 Enable Delay 20 9 Seconds A Adequate overspeed protection required Fuel Limiting C Runtime Fuel Limiting Steady State Fuel Limit 89 8 Runtime Fuel Limiting With Transients Transient Fuel Limit 100 0 Transient Fuel Limit Time 9 7 sec Min 0 0 Max 297 6 Figure 6 6b Configuration Editor Fuel Limiting Tab 5418 2193 software only gt gt Configuration File Editor Configuration1 cfg File Help Dc tal 2 Overview Setpoint Control Modifiers Fuel Limiting Dynamics Discrete KO Alarm Shutdown Security Min Fuel Li
121. ings 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 with optimum rated dynamic curve settings 40 Woodward Manual 26250 L Series Integrated Speed Control For all dynamic configurations the Integral and Derivative settings are constant and do not vary with either engine speed or load Cold Start Timer In demanding genset applications that require G3 performance but are also intolerant of cold start instability the L Series control offers a cold start timer function that sets the gain of the control to a lower than normal value until a programmable amount of time expires This gives an engine time to warm up slightly before switching to a normal gain value The cold start timer can be bypassed by programming a time of 0 seconds 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 settin
122. ion be opposite Friction Dither Setting Sets the position control s friction and dither values This parameter should be set to zero no effect while tuning the PID and then increased for optimum response Increasing this setting increases both the dither amount and a non linear output component If unsure typical values would be between 10 and 25 Allowed values 0 100 Proportional Gain Sets the position control PID s proportional gain Increased gain corresponds to increased PID output higher proportional faster response This setting can also be dynamically adjusted using the PID Tuning screen If unsure a typical value would be 11 8 Allowed values 0 100 Integral Gain Sets the position control PID s integral gain Increased gain corresponds to increased PID output higher integral faster response This setting can also be dynamically adjusted using the PID Tuning screen If unsure a typical value would be 9 8 Allowed values 0 100 Derivative Gain Sets the position control PID s derivative gain Increased gain corresponds to increased PID output higher derivative faster response This setting can also be dynamically adjusted using the PID Tuning screen If unsure a typical value would be 39 2 Allowed values 0 100 70 Woodward Manual 26250 L Series Integrated Speed Conirol Setpoint Tab The setpoint tab provides the speed setpoint configuration settings Based on the security settings the s
123. l be All repair work carries the standard Woodward service warranty Woodward Product and Service Warranty 5 01 1205 on replaced parts and labor 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 and carry with it the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 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 to Woodward for repair please contact Woodward in advance to obtain a Return Authorization Number When shipping the item s attach a tag with the following information e 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 CAUTION ELECTROSTATIC DISCHARGE 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 Packing a Control Use the following materials when returning a complete control e protective caps on any connectors e antistatic protective bags on all electronic modules e packing
124. l communication with the L Series actuator An external RS 232 transceiver is necessary to make communications possible with the Woodward L Series Service Tool A connectivity kit can be purchased from Woodward to accomplish this Further instructions for using this connectivity kit are provided in Chapter 4 24 Woodward Manual 26250 L Series Integrated Speed Conirol It is recommended that the OEM or packager provide a breakout cable that is connected to the L Series service port and run to an easily accessible area on the engine The service port is absolutely necessary to set up and troubleshoot the L Series Amplifier scaled for L Series intended use See Ch 6 Aux 1 0 5 VDC or Aux 1 Input for configuration Remote Speed Setting 73 VDC Pin 8 BI Analog Signal 0 5V Ke Ss Ee Speed Bias OR Signal to Synchronizing Bias Signal SI A Processor 0 5V or 3V 1000pF L Internally selected based on intended use zs 5 32 VDC L Series K Aux 1 TI Aux 1 Input UX Pin 8 Clamp to 5V Discrete Discrete Input Usage en is S SW SE 10k ignal to Closed to Activate Processor 1000pF 10k 0 5 VDC or L Series t3 VDC Aux 2 3 4 Input Clamp to 5V Analog l Command P o D g Aux 2 3 and 4 BN 10k Signal to Analog Input Usage aii Processor 1000pF 499k WY WY 1 9432 VDG L Series Aux 2 3 and 4 Aux 2 3 4 Input Clamp to 5V Discrete Discrete
125. lely on the return spring inside the throttle body assembly to drive toward minimum fuel when not powered Therefore other positive shutdown devices like fuel shut off solenoids are recommended to ensure shutdown on loss of signal to the control system Also separate overspeed trip devices are always mandatory 2 Woodward Manual 26250 L Series Integrated Speed Conirol Basic Control Options Position control with software support for e cw cow clockwise counterclockwise direction control e Field calibration options Speed control with software selectable e Speed setpoints Dynamics Fuel Limiting Start Stop behavior Input Output definitions WARNING ACTUATOR SETUP The actuator must be properly set up using the L Series Service Tool prior to starting the prime mover NOTE The Service Tool is not included but can be downloaded from the Woodward Internet website www woodward com software Programmable Features Control setup and tuning is accomplished through the use of a PC personal computer Woodward Service Tool software and a programming harness The features identified below are described in Chapters 2 and 4 Briefly the E features include Speed Signal Setup Parameters e General Setup Parameters o Fail Direction ccw or cw o Mm Position Direction ccw or cw e Valve Position Control Parameters e Speed Setpoint Setup Parameters o Functionality Settings o _Idle Rated 1 Rated 2 Speed Settings o Ac
126. ll 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 Woodward facility as explained below see Returning Equipment for Repair later in this chapter Charges for the Replacement Exchange service are based on a flat rate plus shipping expenses You are invoiced the flat rate replacement exchange charge plus a core charge at the time the replacement unit is shipped If the core field unit is returned to Woodward within 60 days Woodward will issue a credit for the core charge The core charge is the average difference between the flat rate replacement exchange charge and the current list price of a new unit 116 Woodward Manual 26250 L Series Integrated Speed Conirol Return Shipment Authorization Label To ensure prompt receipt of the core and avoid additional charges the package must be properly marked A return authorization label is included with every Replacement Exchange unit that leaves Woodward The core should be repackaged and the return authorization label affixed to the outside of the package Without the authorization label receipt of the returned core could be delayed and cause additional charges to be applied Flat Rate Repair Flat Rate Repair is available for the majority of standard products in the field This program offers you repair service for your products with the advantage of knowing in advance what the cost wil
127. ll be active conducting when no fault exists but if power is lost or a fault is detected by the L Series actuator the circuit will open See Figure 3 6 below for typical usage of this feature There are two conditions that will prevent the discrete output from operating correctly The first is if battery positive is accidentally connected to it and the second is if it is shorted to ground The circuit will protect itself in the event of a mis wire but it will hold the output open floating until the fault is removed WARNING FAULT PROTECTION It is recommended that the Relay Output be configured for the failsafe Normally On 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 22 Woodward Manual 26250 L Series Integrated Speed Conirol Relay Driver Status back a to Processor From Processor gt 5 32 VDC 500mA maximum a Relay Lamp A 3 Coil Indicator 7 OR r L Series Pin 9 i MS Gs If Protecti sei pie Self Protectin 7 Pe FET 01 uF Ee s Figure 3 6 Relay Driver Output 5V Output pin 7 referenced to pin 3 A 5 Vdc output has been provided on the L Series actuator to power external sensors if necessary The 5 V output is limited to 10 mA but this is sufficient for most light duty ratiometric sensors NOTE All connector pins
128. mit at the same time a non destructive arbitration technique guarantees that messages are sent in order of priority and that no messages are lost Error Handling The error handling of CAN is one of the really strong advantages of the protocol The error detection mechanisms are extensive and the fault confinement algorithms are well developed The error handling and retransmission of the messages is done automatically by the CAN hardware The error handling aims at detecting errors in messages appearing on the CAN bus so that the transmitter can retransmit an erroneous message Every CAN controller along a bus will try to detect errors within a message If an error is found the discovering node will transmit an Error Flag thus destroying the bus traffic The other nodes will detect the error caused by the Error Flag if they haven t already detected the original error and take appropriate action i e discard the current message Woodward 47 L Series Integrated Speed Control Manual 26250 Fine Fault Confinement A faulty node within a system can ruin the transmission of a whole system by occupying all the available bandwidth The CAN protocol has a built in feature that prevents a faulty node from blocking the system A faulty node is eventually excluded from further sending on the CAN bus Bit wise Arbitration The priority of a CAN message is determined by the numerical value of its identifier The numerical value of each message
129. miting NotUsed C Under Torque Limiter Fuel Limiting C Runtime Fuel Limiting Maximum Fuel Limit 89 8 Runtime Fuel Limiting With Transients Input Just E C Runtime Fuel Limiting Curve Input Type Ee Volts d Boost Limit Point 1 24 10 2 247 pont 369 25 1 Points 50 2 70 2 Points 61 2 80 0 Point 5 85 9 100 0 Figure 6 6c Configuration Editor Fuel Limiting Tab 5418 2193 software only Woodward 79 L Series Integrated Speed Control Manual 26250 Min Fuel Limiting Settings Mode Determines the runtime minimum fuel limiting mode This setting is only available in software version 5418 2193 Not Used no min fuel limiting Under Torque Limiter a speed based curve will be used to determine the minimum fuel percentage When this mode is selected curve selections for Max Fuel Limiting are not available Speed rpm Allowed values Each point 5 must be larger than the previous and less than the next value in increments of 16 rpm Limit Sets the minimum actuator positions 5 based on the current speed Allowed values 0 100 Enable Delay sec Determines the delay time before applying the Min Fuel Limiting Allowed values 0 298 sec WARNING OVERSPEED When using an Under Torque Min Fuel Limit adequate overspeed protection is required as the Min Limit function will limit the closing of the fuel valve position command Max Fuel Limiting Settings Mode
130. mproperly tuned dynamics Using Service Tool tune the speed control dynamics Improperly tuned dynamics Using Service Tool tune the position dynamics In most cases the default dynamics are appropriate Friction improperly set Using Service Tool adjust the Friction setting Unable to develop full power Non indexed linkage slipped on shaft Fault detected in control Shorted bad MAP sensor signal Manually verify full travel of throttle plate Using Service Tool view status of fault codes Take appropriate action for active faults If using MAP fuel limiting disconnect starter motor solenoid Verify the input voltage matches expected voltage for known atmospheric conditions Discrete output not working Wiring fault Check the wiring leading to pin 9 for open connections or misconnections Verify that pin 9 is not connected directly to input power or ground Configuration Using the Service Tool verify that the faults and shutdowns are selected properly and that the output is configured for expected operation either normally on or normally off Service Tool not communicating Not Connected status indicated Wiring fault The Service tool is disconnected The wrong communication port has been selected Check AUX3 and AUX4 for loose or misconnected connections Verify harness setup and connections see Chapter 4 Check that Serv
131. mpt to continue normal operation if this fault is detected The value displayed on the Service Tool will show sensed value not default Temp Sense Fail Indicates a failure of the internal on board Temperature Sensor Failure levels gt 150 C and lt 45 C Persistence 650 ms Hysteresis 5 C lt 145 C or gt 40 C to clear Can be configured as an alarm or shutdown If configured as a shutdown the control will drive to Fail Direction using position control if this fault is detected If configured as an alarm the control will internally default to 25 C and attempt to continue normal operation if this fault is detected The value displayed on the Service Tool will show sensed value not default OverTemp If the on board temperature sensor reads above 125 C this error will be set Above 125 C the processor can fail in an unpredictable manner so this fault is recommended as a shutdown The Current Limiting based on temperature will effectively make the output limp by reducing the drive current to zero Failure levels gt 125 C Persistence 650 ms Hysteresis 5 C lt 120 C to clear Can be configured as an alarm or shutdown If configured as a shutdown the control will go limp if this fault is detected If configured as an alarm the control will attempt to continue normal operation if this fault is detected 52 Woodward Manual 26250 L Series Integrated Speed Conirol Position Error Position Err
132. n i Actual Position 50 0 Full Travel Actual Position 30 0 degrees Full Travel Sensor Position 28 3 degrees Minimum Position 0 3 degrees gt VerifyPosition Maximum Position 59 7 degrees Min 0 0 Max 100 0 Finish Figure 7 6 Service Tool Verify Position Calibration Woodward 101 L Series Integrated Speed Control Manual 26250 Manual The Manual position calibration screen figure 7 7 is opened by selecting Manual from the Position Calibration drop down under the Tools menu The manual calibration mode is used to set the minimum position and fail direction and to calibrate the valve to user soft stops inside of any physical stops The first screen to appear when entering the manual mode is used to set the minimum position and fail direction This setting must be correct before manually calibrating the valve Position Calibration xj Setting actuator for wrong direction wv Warning can result in engine overspeed and in personal injury or damage to equipment Selectthe min position and fail direction gt Actuator Direction Min Pos and Fail Dir CCW 7 7 Actuator fails to maximum position e Verify Position Ll ge CCW Finished Figure 7 7 Service Tool Manual Position Calibration The next screen is used to set the minimum and maximum positions for the user soft stops To find the minimum and maximum soft stops use the verify p
133. n According to EMC norm Input Impedance 300 kO in 0 5 V synchronizing mode 10 kQ in 0 5 V remote speed set mode 10 KQ in 3 V synchronizing mode Anti Aliasing Filter 1 anti aliasing pole at 0 5 ms 338 Hz Resolution 10 bits Accuracy 1 6 of full scale over the temperature range of 40 to 125 C including drift I O Latency 6 5 ms Calibration Method 2 point linear software calibration Out of Range Signal none Overvoltage Protection Input protected against 32 Vdc steady state AUX 2 4 Analog Input Parameter Value Input Type 0 5 V Single Ended Input Input Scaling 0 V 0 and 5 V 100 range Max Input Full Scale 5 V 1 Min Input 0 V 1 of Full Scale Isolation None Transient Protection According to EMC norm Input Impedance 499 kO Anti Aliasing Filter AUX 2 1 anti aliasing pole at 0 5 ms 338 Hz Anti Aliasing Filter AUX 3 4 1 anti aliasing pole at 0 001 ms 159 kHz Resolution 10 bits Accuracy 1 3 of full scale over the temperature range of 40 to 125 C including drift I O Latency 6 5 ms Calibration Method 2 point linear software calibration Out of Range Signal none Overvoltage Protection Input protected against 32 Vdc steady state Woodward 123 L Series Integrated Speed Control MPU Input Parameter Value Input Magnitude 1 42 Vrms Frequency Range 1 Hz 12 kH
134. n 2 point linear Out of Range Signal lt 0 25 V or gt 4 75 V Overvoltage Protection Output protected against 32 Vdc steady state if gt 28 V is applied to pin 2 a position related error will be annunciated RS 232 Serial Communication Service Port Parameter Value Isolation None Baud Rate Fixed 19 2 Kbaud Electrical Interface Outputs are TTL level Requires external transceiver for conversion to RS 232 levels for proper communication Pinout Tx pin 4 Rx pin 6 Gnd pin 3 Maximum Cable Length 10 m 33 ft not meant for permanent connection for service only Cable Type Straight through no crossover Woodward 125 L Series Integrated Speed Control CAN Communications optional Parameter Value Type 2 wire CAN version 2 0B CANopen CANopen node ref CiA DS301 Version 4 02 Device Identifier Service Tool software setting Isolation None Baud Rate Fixed 250 Kbaud Pinout Lo pin 6 Hi pin 4 shared with RS 232 communications Line Limitations 40 m 130 ft If an isolator is used Trunk Length 250 m 820 ft Maximum Drop 6 m 20 ft Cumulative Drop 78 m 256 ft Fault Detection Service Tool setting Electronics Temperature Sensor Parameter Accuracy Value 2 C at 25 C ambient 3 C over full range 40 to 125 C Software Execution Rates I O L
135. n 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 This value is not displayed when Ignition is configured Allowed values 1 720 CAN Input settings only displayed in CAN capable versions CAN Fail Timeout Sets the maximum allowed delay time between CAN receive inputs Rx in seconds before a CAN Fault is annunciated Allowed values 0 10 seconds CAN Device Identifier Sets the CAN Device ID COB ID Allowed values 1 127 Heartbeat Producer Time Sets the time increment for sending CANopen NMT heartbeat messages in seconds Allowed values 0 10 seconds Position Control Configuration Settings The position control controls the position of the shaft based on the position command setting from the speed control logic NOTE For most applications the default gains do not need to be changed however Min Position and Fail Direction should be checked Woodward 69 L Series Integrated Speed Control Manual 26250 Min Position and Fail Direction Sets the direction for minimum position and fail direction An alert is displayed Actuator fails to maximum position to warn the user should the fail direction and min fuel direct
136. nal externally Refer to the specifications section for TPS accuracy WARNING TPS OUTPUT Do not try to inject signals into the TPS output as it will negatively impact the performance of the L Series actuator This output is meant to be used with a high impedance device such as a voltmeter Do not tie pin 2 directly to battery or ground If the application does not use this output leave it Woodward 21 L Series Integrated Speed Control Manual 26250 Filtered and Sent to 7 Processor L Series Internal 2 8kQ Pin 2 Position Le e lt Meter AN Sensor SS FE S 01 LiF 1000pF DC Voltmeter B WY L Series Pin 3 Meter VF Figure 3 5 TPS Output Relay Driver Output pin 9 A discrete output is provided to serve as a status indicator This switchable discrete output is a closure to ground capable of sinking 250 mA with an output voltage rise of less than 1 5 V and it is available to power external relays for devices such as alarms or fuel shutoff solenoids The circuit is protected internally against over current and inductive spikes so external clamping is not necessary This output can be configured to be either normally on closed preferred failsafe setting or normally off open In addition the faults that drive the relay status can be configured individually For details refer to Chapter 4 Service Tool By default this circuit will be configured in a failsafe manner meaning it wi
137. ne 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 see Discrete I O tab 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 see Discrete I O tab Analog Input Selection Configures the analog input to the AUX hardware input A normal input is scaled such that 0 V input provides the minimum speed setting anda 5 V input corresponds to the maximum setting as defined by the Bias Limit or Low High Limit settings An inverted input selection is available to reverse the direction resulting in a 5 V minimum and a 0 V maximum speed setpoint command 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 NOTE 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 Lower Rate Specifies the ramping rate for the speed setpoint Lower function Only displayed if the Raise Lower function is configured Allowed values 1 1000 rpm s Raise Rate Specifies the ramping rate for the speed setpoint Raise
138. nected to the Service Tool The Aux 3 amp 4 Simulated Analog inputs Manual 26250 simulate a fixed value analog input signal in percentage and the discrete inputs can be simulated as closed checked and open unchecked using the Simulated Discrete Input checkboxes Y L Series Service Tool ES loj x File Communication Tools Help Control Mode Stopping Speed Setpoint 2179 5 rpm Position Setpoint 00 Actual Speed 2179 5 rpm Actual Position 0 2 Overview Alarms Shutdowns Internal Shutdowns Simulated 10 identification Simulated Analog Input Aux 3 mS Aux 4 WEE Simulated Discrete Input I Aux 3 On I Aux 4 On Connected 2S Alarm x Shutdown Figure 5 7 Service Tool Simulated I O Tab 64 Woodward Manual 26250 L Series Integrated Speed Conirol Identification Screen To monitor the L Series product identification go to the Identification page on the main window Information displayed includes the part number of the embedded L Series software the serial number of the unit the configuration filename and the date of the last configuration change The Software Part Number identifies the embedded firmware part number and revision The Serial Number is a Woodward tracking tool and is set at the factory The Configuration Identifier displays the first 8 characters of the loaded configuration file and the Date of Last Configuration Change can be used to track changes to produc
139. nterface is an interface which offers equivalent common mode and differential mode conditioning of that of a grounded 24 V lead acid battery Dress the harness with wire loom to contain it in a single bundle Use grommets when passing the harness through metal panels Connector The following Deutsch connector components are recommended for harness designs Recommended Optional Mating Connector DT06 12SA P012 DT06 12SA Secondary Lock W12S P012 N A Sockets 0462 201 16141 0462 201 16141 For convenience Woodward part number 8928 396 is a kit that provides all the necessary Deutsch components CAUTION WIRING 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 3 1a 3 1b 16 Woodward Manual 26250 L Series Integrated Speed Conirol 6A FUS CO QO POWER INPUT 1224 VDO a TPS OUTPUT gt LT THROTTLE POSITION 0 75VDC TO 4 25VDC Voltmeter MPU AUX SIG GND o L AUX 3 INPUT CAN HI AUX3 CAN H RS232 TX gt e SERAL CON AAAA INPUT POWER GND AUX 4 INPUT CAN L m SERIAL COM AAAA AUX4 CAN L RS232 RX D 5 gt TO SENSOR S 5V OUT 5V 12V 24V T AUS 1 DISCRETE INPUT Ar O
140. o with ramp StartSpeed1Threshold f 23 mm StartSpeed2Threshold 48 rpm Start Speed Hysteresis 16 rpm Actuator Ramp Rate 1 176 fsec Start Fuel 1 102 Start Fuel 2 20 0 Max Starting Time 19 5 see Run Speed Threshold 80 rpm Engine Stopping Settings Stop Speed Threshold 64 rpm Stopped State Holding Current 9 8 Stopped State Delay 0 0 see Error Detection Governing Error Low Range 30 rpm Governing Error Low Time 1039 set Governing Error High Range 20 rpm Governing Error High Time 1039 sec Overspeed Threshold 4080 rpm Values are constrained by each other in increments of 8 in the following order Start Speed Hysteresis Start Speed 1 Start Speed 2 Stop Speed Run Speed Figure 6 4 Configuration Editor CONTROL TAB 72 Woodward Manual 26250 L Series Integrated Speed Conirol The L Series speed settings must follow the following general order Start Start Stop Run Rated Start Speed Speed Speed Speed Speed Overspeed Speed 1 2 Hysteresis 0 0 Normal Operating Speeds Starting the Engine The engine starting sequence will look like this if no errors are detected While in power down enable the control by the Run enable input The actuator will go into position control and the control is ready Start the engine The engine speed will increase above the Start Speed 1 Threshold and will go to the Start Fuel position demand The control is still running open loop
141. of the complete configuration and are not password protected When this feature is used the complete configuration is typically password protected The settings in this window can only be changed while connected to the control on line and when the engine is stopped speed is zero This option is only available if the Allow unsecured tuning of speed input and speed settings and or Allow unsecured tuning of under torque fuel limiter settings are selected on the Security tab in the Configuration Editor The settings available are dependent on software version and configured options The Modifiers tab is only available in Service Tool version 2 1 and newer For details on the parameters that appear in this window refer to Chapter 6 96 Woodward Manual 26250 L Series Integrated Speed Conirol L Series Service Tool File Communication GOEN Help Control Mode Position Calibration gt EE Edit Position PID ae Well Edit Speed Dynamics Meroe Actual Speed Edit Configuration Settings Overview Alarms Shutdowns Internal Shutdowns Simulated io Ic Figure 7 2a Edit Configuration Settings Menu 5418 2193 software only L series Speed Settings L series Speed Settings t Speed Setpoints Modifiers Speed Input Modifiers 2 Stroke 4 Stroke Number Of Cylinders Idle Setpoint 800 0 rpm Number Of Cylinders Averaged Rated Setpoint 1800 0 rpm Number Of Teeth Per Engine Revolution 6
142. oided could result in damage to equipment or property A NOTE provides other helpful information that does not fall under the warning or caution categories Revisions Text changes are indicated by a black line alongside the text Woodward Governor Company reserves the right to update any portion of this publication at any time Information provided by Woodward Governor Company is believed to be correct and reliable However no responsibility is assumed by Woodward Governor Company unless otherwise expressly undertaken Woodward 2004 All Rights Reserved Manual 26250 L Series Integrated Speed Conirol Contents REGULATORY COMPLIANCE 00 ccecececceeseseeeeeeeeceeeaeesseseeeeeeeseenesseneeeeeseenoas V ELECTROSTATIC DISCHARGE AWARENESS c ccsseseeeeccenseescneaseeseneaseesees Vi CHAPTER 1 GENERAL INFORMATION cccceseeeeeeeeeeeeeeeeeeseeeeeenseeneeeeneeeenees 1 PURPOSE and SCOPE cainii aai aa aaa aaa aai Raai 1 How to Use This Manual 1 Intended Applications ccccccceceececceceeeeeeeeeeneeeaeeeeeeeeeseceeaeeeeeeeseseceieaeeeeeeeeeteees 1 WATROGDUCUION 3 az acctsiedelcctteiactstavectecsiesteaaleccuncetiaiecdscasaadianssedenueuneaedsessadenusenendacersatencedsy 2 Basic Control Options sisian anenai reinaan ia eaaa aa aaiae aiana a aaae aiaa 3 Programmable Features 3 Service Tool Goftware 4 CHAPTER 2 MECHANICAL INSTALLATION cccssssesseeeeeeeseecesesssneeeeeeeeeeanenees 5 virge eiert 5 Gen
143. om 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 Gas Engine Stops Butterfly valves in carburetors will often bind if rotated too far toward minimum or maximum For this reason hard stops in the throttle body or associated linkage should be used at both minimum and maximum positions The engine must always shut down when the actuator is at the minimum stop Linkage Proper design and installation of the linkage from the actuator to the engine is necessary for the unit to provide the best control possible The characteristics of the engine fuel system and the control dictate the linkage design Most diesel fuel pumps have a linear relationship between metering valve or fuel rack position and the amount of fuel delivered to the engine Throttle bodies have a non linear relationship between throttle angle and air fuel flow Woodward 7 L Series Integrated Speed Control Manual 26250 Because the L Series is a linear control a linkage designed for diesel applications tends to maintain a 1 1 relationship between actuator shaft angle and rack position throughout the range of travel A linkage designed for gas or gasoline applications tends to start with a 3 1 relationship transitioning to a 1 3 relationship between actuator shaft angle and throttle angle throughout the range of travel This non line
144. ontrol Manual 26250 m Position Calibration Figure 7 9 Service Tool Auto Position Calibration 104 Woodward Manual 26250 L Series Integrated Speed Conirol Chapter 8 Troubleshooting Introduction This chapter presents several broad categories of application failures typically experienced in the field possible causes and some tests used to verify the causes Because the exact failure experienced in the field is the product of the mechanical electrical failure combined with the configuration file resident in the control it is left as the OEM s responsibility to create a more detailed troubleshooting chart for the end user Ideally this end user troubleshooting chart will contain information about mechanical electrical engine and load failures in addition to the possible governor failures For more detailed information about governor system failure modes and effects contact Woodward for a copy of the system DFMEA The troubleshooting scenarios listed below assume that the end user has a digital multimeter at his disposal for testing voltages and checking continuity and assume that the application has been engineered and tested thoroughly There are four parts to the troubleshooting section e General Troubleshooting e _Engine Generator Troubleshooting e Troubleshooting Alarm Shutdown Diagnostic Flags e Input Output 1 0 Troubleshooting WARNING SAFETY RECOMMENDATIONS The actions described in this trou
145. ontrol and the position is set to the position the control was at when the screen was entered The screen displays the User Requested Position Actual Position Minimum Position and Maximum Position These User Positions are calculated from the user calibrated stops The Full Travel Actual Position is the full stroke factory position without user stops after software linearization The Full Travel Sensor Position is the full stroke factory position without user stops before software linearization The Full Travel Sensor Position will match the TPS Output Signal The Verify Position screen can be used to check the calibration or to get the minimum and maximum position values for the manual calibration If the Enable Requested Position Tuning box is checked the valve can be positioned anywhere from 0 to 100 of the user minimum and maximum stops by entering a value into the Requested Position If the Enable Requested Position Tuning box is unchecked the valve will go limp and can be physical positioned by hand NOTE If the full factory position calibration range is not being used the Manual or Automatic Calibration has been performed and the minimum position direction is changed the calibration must be run again for the Verify Position mode to work correctly Position Calibration 4 xj Move the valve position by setting the requested position or by manually moving the output MV Enable Requested Position Tuning Requested Positio
146. or detection logic will indicate a difference between commanded position and actual position exceeded for longer than the set delay The error magnitude and duration are customer configurable parameters Failure levels Set by customer variable Error gt PosErrorMax Persistence Set by customer variable Position Error Delay Hysteresis none Override Whenever the current is being limited to a factor of 1 2 normal maximum or less This would be because of high temperature see section on Temp Sensing and Current Limiting or a shutdown that causes the output to go limp Can be configured as an alarm or shutdown If configured as a shutdown the control will drive to Fail Direction using position control if this fault is detected If configured as an alarm the control will attempt to continue normal operation if this fault is detected Relay Output Shorted The relay driver is thermally protected against wiring errors If incorrectly wired the output will turn off and then set the Error Bit Can be configured as an alarm or shutdown If configured as a shutdown the control will drive to Fail Direction using position control if this fault is detected If configured as an alarm the control will attempt to continue normal operation if this fault is detected Speed Input Failed Speed input signal failed indication Dedicated shutdown The control will drive to Fail Direction using position control if this fault is detected The con
147. osition mode described above to position the valve and use the Full Travel Actual Position reading for minimum and maximum position values NOTE After leaving this mode power must be cycled for the new settings to take effect 102 Woodward Manual 26250 L Series Integrated Speed Conirol Position Calibration B x Setthe minimum and maximum positions for the v Warning actuator Minimum Position 0 3 degrees Maximum Position 59 7 degrees x Actuator Direction gt Verify Position Finished Figure 7 8 Service Tool Manual Position Calibration Settings Automatic The Automatic position calibration screen Figure 7 9 is opened by selecting Automatic from the Position Calibration drop down under the Tools menu The automatic calibration mode is used to set the minimum position and fail direction and to calibrate the valve to user physical stops mechanical hard stops Like the manual mode the first screen to appear is used to set the minimum position and fail direction This setting must be correct before automatic calibration is performed After setting minimum position and fail direction the screen below will appear The control is now moving first to the ccw stop and then to the cw stop to get the physical minimum and maximum positions NOTE After leaving this mode power must be cycled for the new settings to take effect Woodward 103 L Series Integrated Speed C
148. ound pin while the engine is starting firing Check tune position dynamics using the Service Tool Perform a position calibration Check all mechanical linkages and stops Verify Configuration errors settings Position Sensor Failure If the internal position sensor is outside the diagnostic limits Internal failure of position sensor Return unit to Woodward Internal Shutdown All internal shutdowns will set this flag The Control is defective Return unit to Woodward EEPROM Failure The software can t write to the EEPROM The software can t read from the EEPROM The Control is defective Return unit to Woodward 112 Woodward Manual 26250 L Series Integrated Speed Conirol Error Flag Description Possible Source Possible Action Brown Out Reset The brown out detection flag indicates that power to the control has sagged to a point of non operation and is now restored Power source voltage drop Loss of power or intermittent power supply wiring Power supply wiring too long or too thin L Series will reset during transient power uses Possible power problem Check wiring for bad or lost connection Make sure wiring is of the correct thickness and length according to manual Watchdog Reset The watchdog has reset the Control After software update the software watchdog will reset the Control The software is disr
149. out Incorrect or intermittent wiring problem Incorrect configuration Device not sending updates fast enough or regularly bursts Check wiring for bad or lost connection Verify configuration Verify ECM messages and update rates Verify configuration of L Series min update rate Woodward 113 L Series Integrated Speed Control Manual 26250 Electrical Troubleshooting Guide MPU Speed Input If the speed input is not functioning properly verify the following e Measure the input voltage and frequency e Check the values seen by the L Series driver using the Service Tool and verify that is matches the input signal e Check the wiring Look for loose connections and disconnected misconnected cables connections e Check the software configuration to ensure that the input is configured properly Ignition Speed Input If the speed input is not functioning properly verify the following e Measure the input voltage and frequency e Check the values seen by the L Series driver using the Service Tool and verify that is matches the input signal e Check the wiring Look for loose connections and disconnected misconnected cables connections e Check the software configuration to ensure that the input is configured properly Analog Input If an Analog Input is not functioning properly verify the following e Measure the input voltage e Verify the input is properly configured e Check the
150. ower to the rotary actuator to 25 W at any given time and input voltage in the valid range The control system should be protected with a 6 A fuse in the voltage supply lines Typical max average current is 2 1 A or max 25 W at 12 V The application should be configured to turn on power to the actuator when the engine is first cranked Shielded Wiring The use of cable with individually shielded twisted pairs is required where indicated by the control wiring diagram Figure 3 1 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 or an undesired ground loop condition may occur If it becomes necessary to terminate the shield at the end opposite of the L Series it must be done through a high frequency capacitor Installation Notes e Wires exposed beyond the shield should be as short as possible not exceeding 50 mm 2 inches e 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 e 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 at the time of installation is required to assure satisfactory oper
151. peed setpoint configuration settings with the exception of the mode can also be modified from the Edit Speed Settings selection under the Tools menu refer to Chapter 7 Editing of Speed Settings Configuration File Editor Configuration1 cfg DI xj File Help oela H Overview Setpoint Control Modifiers Fuel Limiting Dynamics Discrete I O Alarm Shutdown Security Speed Setpoint C Rated Idle Setpoint 800 0 rpm Rated 1 Setpoint 1800 0 rpm C Idle Rated Rated 2 Setpoint 1500 0 rpm Acceleration Ramp Rate 50 0 rpmisec Deceleration Ramp Rate 50 0 rpmisec C Runtime Select Rated 1 2 Ramp Rate to Idle 1 2 rpmisec C Startup Select Rated 1 2 Figure 6 3 Configuration Editor SETPOINT TAB Mode The Mode determines how the speed setpoint will function This setting determines the display of additional 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 see Discrete I O tab Start up Select Rated 1 2 Setpoint uses 2 rated speeds selected on unit start up Must configure a Rated2 discrete input to provide this function see Discrete I O tab Runtime Select Rated 1 2 Setpoint uses 2 rated speeds selectable at any time Must configure a Rated2 discrete input to provide this function see Discrete I O tab Idle Rated 1 Rated 2 Thr
152. peration Check wiring Set up the correct input modes Configure the Control for Idle Rated operation if that is the desired operation mode The engine will not go to idle speed The Idle Rated input wiring is defective See overview screen for input position The high low and active open or closed selection for the Idle Rated input is selected incorrectly The Control is not configured for Idle Rated operation Check wiring Set up the correct input modes Configure the Control for Idle Rated operation if that is the correct operation mode The engine will not raise the speed setpoint The Raise input wiring is defective See overview screen for input position The high low and active open or closed selection for the Raise input is selected incorrectly The Control is not configured for Raise Lower operation The Lower input is also active and the Analog Raise Lower is configured The lower is active and only Raise Lower is selected The Control will lower the speed if Raise and Lower are selected at the same time Check wiring Set up the correct input modes Configure the Control for Raise Lower operation or Raise Lower and Analog if that is the correct operation mode Set up the lower input to the correct state The engine will not lower the speed setpoint Set up the lower input to the correct state The engine will not lower the speed setpoint The engine will not
153. pes cabinets equipment etc 2 Avoid the build up of static electricity on your body by not wearing clothing made of synthetic materials Wear cotton or cotton blend materials as much as possible because these do not store static electric charges as much as synthetics 3 Keep plastic vinyl and Styrofoam materials such as plastic or Styrofoam cups cup holders cigarette packages cellophane wrappers vinyl books or folders plastic bottles and plastic ash trays away from the control the modules and the work area as much as possible 4 Do not touch the electrical conductors the connectors or the components with conductive devices or with your hands CAUTION ELECTROSTATIC DISCHARGE 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 vi Woodward Manual 26250 L Series Integrated Speed Conirol Chapter 1 General Information SSS eee Purpose and Scope The purpose of this manual is to provide the necessary background information for applying the L Series integrated speed control to diesel and gas gasoline reciprocating engines Topics covered include mechanical installation electrical wiring software programming and troubleshooting While this manual is primarily targeted at OEM customers OEMs themselves may find it useful to copy som
154. pm Actual Position 0 0 Overview Alarms Shutdowns Internal Shutdowns Simulated 10 Identification Start Fuel 0 0 ao Li Min Fuel Limit 0 0 LSS W Max Fuel Limit 99 6 Raw Position Demand 0 0 rpm 00 Hi HSS Run Enable W Idle Rated Linearize Actual Position Supply Voltage 27 5 Volt Gain 0 100 rpm H Electronics Temperature 32 7 C Integral 0 08 1 sec Bicceteoumet Derivative 0 17 sec Si H GET T ter Full Travel Position Setpoint 8 0 Ser R AG dee Full Travel Actual Position 79 Full Travel Sensor Position 8 1 Connected 7 Alarm 27 Shutdown Figure 5 3b Service Tool Overview Tab 5418 2193 software only 60 Woodward Manual 26250 L Series Integrated Speed Conirol 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 between the electronics module and the LAT motor 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 Full Travel Position Setpoint Indication of the position setpoint in terms of total overall unit travel Useful if a less than full travel user calibrated range is used Full Travel Actual Posi
155. problem solving during normal business hours Emergency assistance is also available during non business hours by phoning our toll free number and stating the urgency of your problem For technical support please contact us via telephone email us or use our website and reference Customer Services and then Technical Support Product Training is available at many of our worldwide locations standard classes We also offer customized classes which can be tailored to your needs and can be held at one of our locations or at your site This training conducted by experienced personnel will assure that you will be able to maintain system reliability and availability For information concerning training please contact us via telephone email us or use our website and reference Customer Services and then Product Training Field Service engineering on site support is available depending on the product and location from one of our many worldwide locations or from one of our authorized 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 field service engineering assistance please contact us via telephone email us or use our website and reference Customer Services and then Technical Support Woodward 119 L Series Integrated Speed Control Manual 26250 Technical Assistance If you need to telephone for technical assistance you will n
156. r with improper use of these software tools Only trained personnel should have access to these tools The current L Series control configuration settings can be viewed at any time when connected to the control by opening the Configuration Editor File Open Control Configuration assuming password protection is not active See Figure 6 1 NOTE If using dynamics curves or fuel limiting curves control power must be cycled after loading a new configuration before the new settings will take effect On CAN versions the Communication Connect command must be issued prior to powering up the L Series Since the same I O pins are used for both Service Tool and CAN communications the only time the Service Tool is enabled is on power up If a Service Tool connect is detected CAN will be disabled and the Service Tool communications will remain active OEM Configuration File Data The OEM can save configuration file specific data with the service tool by selecting Properties under the File menu pull down This is a text field and can be used to store data such as e Customer e Engine Type e Application Type e Notes 66 Woodward Manual 26250 L Series Integrated Speed Conirol Configuring the Unit On Line Unit 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 L Series cont
157. raise and lower inputs A 0 to 5 Vdc analog input provides for remote speed setpoint control A 3 Vdc analog input provides for isochronous load sharing and synchronizer control Figure 4 2 provides a detailed overview of the setpoint modes and rates available Woodward 33 Manual 26250 L Series Integrated Speed Control aAnoy J N4 VIS D sen y dwey ap 0 pajqesip ei 013U09 pasn ajes dwiey 9999 2292y oeeeeeescan p ds y abug SIU uj Dasn a1pI dUuIE 13M07 SILY es D pasn ayes dwey Dogeug Le sabueypd julod jas paads on e emm el H Cd k pu sb 1009 gt e DN 1 00r 4 d D aa PILY E au IPI Cd a si S 009 julod jas p ds out UO Laus a S ou aAEU Uiaa Boyeuy pue Le 1J m0 asiey abugI SIY UJ ch HUI eng IPON 008 D bt av asiey aNv peH D S OO l OOfzl julod yas payey 0094 BAHOY OSIE SI ap ng S OARDE Z Dag Bojeuy uemo7 esiey a H Y mod jag z parey 0084 p eanoe yI zuiod Jas p ds d 84 p y Ui Hoyeuy pue S 1 M0 asiey a6ues SIY UJ yun edd sayipow Woodward Figure 4 2 Speed Setpoint Actions and Rates 34 Manual 26250 L Series Integrated Speed Conirol Speed Setting and Ramp Functions The control provides run idle and two rated speed set points with a lower and raise limit plus accel and decel ramps raise and lower ramps and a ramp to idle rate All ramp rate settings ar
158. rloading at rated speed or to merely limit fuel delivery to the engine for other situations such as to prevent detonation Adjusting the Max Fuel Limit to 100 percent disables the function Transient Fuel Limit The Transient Fuel Limit setting allows a temporary increase to the fuel demand above the maximum steady state fuel limit setting for a set transient time period This can improve a load on transient response by allowing a momentarily higher fuel demand The fuel limits are 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 Woodward 43 L Series Integrated Speed Control Manual 26250 Boost External Fuel Limit Function External fuel limit is a software adjustable five breakpoint curve based on an external transmitter 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 4 8 The engineering units for each breakpoint are in percent and user set input units The l
159. rol NOTE As changes are made to Configuration parameters they are not used by the driver 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 configuration is summarized as follows 1 Open the Configuration Editor Dialog using the File New or File Open options 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 L Series Service Tool E ll x ACE Communication Tools Help New Configuration Engine Stopped Open Configuration File a re a Position Setpoint 0 0 Open Control Configuration Actual Position 00 Overview Alarms Shutdowns Internal Shutdowns Simulated 10 Identification Giant Fuel 0 0 SS 2 Li Fuel Limit 99 6 Sk a Speed Setpoint Raw Position Demand 0 0 Target Setpoint 0 0 rpm MPU Speed Input Run Enable i Supply Voltage 20 9 Volt i Electronics Temperature 33 7 C Dmamics Gain 0 036 irpm 2 Discrete Output Integral 1 20 Liser ae k Full Travel Position Setpoint 0 5 Derivative 0 01 sec SS e Full Travel Actual Position 0 5 Gain Window 20 0 rpm i 8 y Full Travel Sensor Position 0 0 Gain Ratio 1 00 ratio Connected AA Alarm X Shutdown Figure 6 1 Configuration Selec
160. rt Fuel Limit not set properly Speed sensing error Acceleration ramp rate is set too high Verify the overspeed trip setting configuration Verify the input speed configuration settings number of teeth Check the sensed speed compared to an external engine speed indicator If overspeed occurs on transient raise common gain to reduce overshoot Lower rpm run threshold or lower start fuel position Follow instructions for MPU or ignition signal intermittent under Speed Sensor Error Engine starts but shuts down on error Incorrect mode of operation speed speed bias function dynamics Speed sensing error Error detected by control AUX inputs shorted or open Follow instructions for MPU or ignition signal intermittent under Speed Sensor Error Verify the exact cause of the error using the Service Tool Disconnect starter motor solenoid Disconnect harness from governor Check for correct voltage level between AUX pin s under question and ground pin for known application modes Woodward 107 L Series Integrated Speed Control Manual 26250 Problem Possible Cause Suggested Tesi Correction The engine will not go to rated speed The Idle Rated input wiring is defective See overview screen for input position The high low and active open or closed selection for the Idle Rated input is selected incorrectly The Control is not configured for Idle Rated o
161. rt number 9927 1222 L Series Service Tool CAUTION SERIAL PORT DAMAGE There is a potential for serial port damage when communicating with the L Series 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 L Series 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 ei zm zg To PC loaded with Service Tool Woodward Kit 8923 1061 fie 9 Pin Straight S Thru Cable T TLL 2 1232 Loa To L Series Actuator Engine lt Control Harness ei L y Pinouts Viewed Looking into Control Connector and Computer Connector Figure 5 2a Programming Harness Connections 56 Woodward Manual 26250 L Series Integrated Speed Control e _ ToPC eee loaded with Service Tool Q12 O 40 32VDC O11 20 O10 30 GND E e h fp O9 4O Pin 2 J S Pin 3 r N uar aE f 9 Pin Straight Os a
162. s To use this mode requires aux inputs to be configured for a Raise a Lower and an Analog input When a Raise command is activated the setpoint increases and when a Lower command is activated the setpoint decreases The Analog input is selected when both the Raise and Lower inputs are activated General Speed Setpoint Comments H Idle Rated is configured the selection of idle setpoint has priority over the raise lower and analog setpoints The idle setpoint must be unselected rated setpoint selected to activate the raise lower and analog setpoints If configured the analog setpoint has priority over the rated setpoint If the analog setpoint is selected when the idle rated input is switched to the rated position the setpoint will ramp to the analog setpoint rather than the rated setpoint Speed Control Dynamics The control algorithms used in the L Series control are designed specifically for reciprocating engine applications The L Series 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
163. s Service Tool A connectivity kit can be purchased from Woodward to accomplish this Further instructions for using this connectivity kit are provided in Chapter 4 It is recommended that the OEM or packager provide a breakout cable that is connected to the L Series service port and run to an easily accessible area on the engine The service port is absolutely necessary to set up and troubleshoot the L Series Any RS 232 wiring must meet the requirements in the EIA RS 232 Standard document The RS 232 standard states that the length of the RS 232 cable between the driver and the PC must be less than 50 ft 15 m with a total capacitance less than 2500 pF The RS 232 data rate is fixed at 19 2 kbps The communication port is non isolated and susceptible to both EMI noise and ground loops related to PC connections and typical industrial environments Functions available through the Service Tool include tuning monitoring and configuration of the position controller Detailed driver status information is also available For details refer to the Service Tool chapters of this manual NOTE The service port is not isolated and is not intended to function while the prime mover is in normal operation The service port is provided for configuration and setup only CAN Connections pin 4 CAN HI and pin 6 CAN LO As a general rule for CAN networks use the following and refer to the table below e Wiring length restrictions depend on the baud
164. settings gt gt Configuration File Editor Configuration1 cfg oO x File Help Deg aal gl Overview Setpoint Control Modifiers Fuel Limiting Dynamics Discrete vo Alarm Shutdown security Shutdown Alarm Temperature Sensor Failed ci C Supply Voltage Fault Ze E Relay Fault Ze C Over Temperature Ze C Position Error Ze C Governor Error High o Governor Error Low o C At Minimum Fuel Limit ce C Enable Fault Latching Position Error Maximum 2 4 of stroke Position Error Delay 2 0 sec Figure 6 9 Configuration Editor Alarm Shutdown Tab Alarm Shutdown Fault Settings Fault Selection Shutdown or Alarm Set the desired action for each of the faults from the list Setting the selection to a Shutdown will position the output to the configured Fault Direction see Overview tab Setting the selection to an Alarm will allow the unit to attempt to continue running For details on each of these fault conditions refer to the Fault section in the manual Chapter 4 Temperature Sensor Failed Supply Voltage Fault Relay Fault Over Temperature Position Error Governor Error High Speed Governor Error Low Speed At Minimum Fuel Limit 5418 2193 software only CAN Fault 5418 2226 software only Woodward 87 L Series Integrated Speed Control Manual 26250 The following conditions are dedicated shutdown conditions EE Prom Fail Position Sensor Failed Overspeed Max Starting Tim
165. ssacesnes 66 Ovetrvlew 66 Configuration Sen 67 Load Configuration File to Control 91 Configuration EE 92 Woodward L Series Integrated Speed Control Manual 26250 Contents CHAPTER 7 SETUP AND TUNING isssessssisssssscscstacsiensnisistaesuntannsnavictsasansnsnnsescnes 95 INEOAUC EE 95 Tuning the Speed PID saviicieseshiceceetewsesetenerbene a dee tiene TEE ESE 95 Editing of Configuration SettingS 2 0 00 ecceeeeeeeeeeeeneeeeeeeeteeeeeeeeeeeeaaeeeeeenaeeeeeeaas 96 Tuning the Position PID 3 2ctiesecteceestevteseseccrseseneiesaueeneeteatneeesnens AER 98 Position Calibration and Vertication nennt 100 Calibration Sequence OVErView ceeceeeeceeceeeeeeeteceeeaeeeeeeeeeeeecenaeeeeeeetenenes 100 Position VenifiCatlon i siccicccsesesiiceeesnsdetersesbccdesisreesveveeenceeeeiaceuaseanacerneviuevecteqneezacty 101 CHAPTER 8 TROUBLESHOOTING cccccssssssseeeeeeecescesesseneeeeeceecesesseneeeensoees 105 INthOGUCTION yo piae maae ot ape eee ses a a ee 105 General System Troubleshooting Guide 0 0 00 eee ceceeeeeeeeeeeeteeeeeenneeeeetneeeeeeeaes 106 Engine Generator Troubleshooting ccccceesceceeeeeseeeeeceeeeeeeeeecueeeseaseseeeeees 106 Troubleshooting Diagnostic Fault Flags ccceeeeseeeeeeeeeeeeeeneeeeeeennaeeeeneaes 110 Electrical Troubleshooting Guide ccccceeeeeeeeeeeceeeeeeeeecenaeeeeeeeetteeseaeees 114 CHAPTER 9 SERVICE OPTIONS 11 ssscsssssssssnnnnsecsersssesssnnnneceerssssesssenens
166. t board magnetic pick up original equipment manufacturer pulse width modulated revolutions per minute a communications standard throttle position sensor 121 L Series Integrated Speed Control Manual 26250 Appendix B L Series Control Specifications e Specifications Power Supply 12 24 V systems 10 32 Vdc reverse polarity protection 2 5 A max Power Consumption 32 W maximum Torque Nominal 0 34 N m 0 25 Ib ft Minimum Transient up to 105 C 0 28 N m 0 21 Ib ft Minimum Continuous up to 105 C 0 20 N m 0 15 Ib ft Mass Weight 425 g 15 oz Power Up to Operation Time lt 250 ms lt 1 s CAN version Performance Speed Control Accuracy MPU Input 0 25 of rated speed on gasoline diesel or gaseous engines IGN Input 0 5 of rated speed on gasoline or gaseous engines Transient Behavior Gasoline lt 10 at 100 load shed lt 10 at 100 load pick up Gaseous lt 10 at 100 load shed lt 10 at 100 load pick up Diesel lt 10 at 100 load shed lt 7 at 100 load pick up NOTE The specifications above are for naturally aspirated engines Turbo diesel applications can vary in the amount of load that can be picked up within these specifications Contact Woodward or consult IS03046 4 and or ISO8528 5 with questions about turbo specifications Recovery Time 3 seconds Environment Ambient Operating Temperature 40 to 105 C 40 to 221 F 40 to 70 C 40 to 158 F CAN version
167. t configuration settings gt L Series Service Tool lol x File Communication Tools Help Control Mode Engine Stopped Speed Setpoint 0 0 rpm Position Setpoint 00 Actual Speed 0 0 rpm Actual Position DA o Overview Alarms Shutdowns Internal Shutdowns Simulated 1O Identification Software Part Number 5418 1680 B Serial Number 12345678 Configuration Identifier test 324 Date of Last Configuration Change Jun 9 2004 Connected Os Alarm 777 Shutdown Figure 5 8 Service Tool ldentification Tab Woodward 65 L Series Integrated Speed Control Manual 26250 Chapter 6 Configuration Overview The L Series is configured using the Service Tool Refer to Chapter 5 for Service Tool installation and connection instructions The L Series 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 L Series control Off line configuration can be done at any time however settings will not take effect until they are loaded into the control NOTE Many applications are delivered pre configured calibrated and tuned These units do not require the use of the Service Tool NOTE Configuration reading and loading can be individually password protected for security purposes If security is applied these features will not be accessible without the password WARNING TRAINED PERSONNEL An unsafe condition could occu
168. tab provides speed control dynamics settings The dynamic settings can also be adjusted from the Edit Speed Dynamics screen during run time gt Configuration File Editor Configuration1 cfg iol x File Help olem H Overview Setpoint Copal Modifiers Fuel Limiting Dynamics Discrete vo AlarmiShutdown Security C Single Cold Start Gain 0 01 irpm Delay switch In sec Dual Cold StartTime 0 0 sec Dynamics 1 Dynamics 2 C Rated Integral 1 20 jee C Idle Rated Derivative oot sec C Rated Curve Gain Window 20 0 rpm Gain Ratio 1 00 Common Gain 8 00 ratio of gain curve Position Rated Gain rpm Idle Gain reng Gaint 00 one Gain 2 20 0 Gain 3 40 0 Gain 4 89 8 Gain5 100 0 fon 020 nm 080 Figure 6 7 Configuration Editor Dynamics Tab Dynamics Settings Overall Mode Set to Single or Dual dynamics If Dual is selected must configure a Dual Dynamics discrete input to provide this function see Discrete I O tab Cold Start Gain Sets the gain to be used during a start Typically this is set to a lower than normal gain value To disable the Cold Start Gain set the Cold Start Gain Timer to zero Allowed values 0 0 778 rpm Cold Start Gain Timer Sets the number of seconds the Cold Start Gain is used during a start To disable the Cold Start Gain set the Timer to zero Allowed values 0 300 s Delay switch between Dyn 1 and Dyn 2 The dela
169. ted On No Load 0 0 of Actuator Position Digital Input Full Load 100 0 of Actuator Position Bias C None Input Jang C Raise Lower Input Type Io a Volts z C Analog Max Analog Rate 12 5 romi sec Lower Rate 12 5 rpmisec Raise Rate 12 5 rpm sec Analog or Raise Lower C Load Share Syne Operation Low 1696 rpm eR if Hi 1888 rpm Figure 6 5 Configuration Editor Modifiers Tab Droop Settings Droop Mode Determines what methods of adjustment of the speed setpoint are to be allowed Oft 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 see Discrete I O tab 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 76 Woodward Manual 26250 L Series Integrated Speed Conirol 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 what methods of adjustment of the speed setpoint are to be allowed No
170. the Rated curve dynamics option for dynamics 2 the Rated curve or Idle Rated curve option must be selected for dynamics 1 See the Dynamics tab 92 Woodward Manual 26250 L Series Integrated Speed Conirol 14 15 16 17 18 19 20 21 22 23 24 25 26 Woodward When dynamics 2 is set to idle rated curve mode dynamics 1 must be in idle rated curve mode An incompatibility between the Dynamics modes has been detected To use the Idle Rated curve dynamics option for dynamics 2 the Idle Rated curve option must also be selected for dynamics 1 See the Dynamics tab Configured Dual Dynamics but no Dual Dynamics discrete in An incompatibility between the Dynamics mode and Dual Dynamics discrete input is detected To use the Idle Rated dynamics option the Dual Dynamics discrete input cannot be Always Off See the Dynamics and Discrete I O tabs Configured Idle Rated Dynamics but no Idle Rated discrete in An incompatibility between the Dynamics mode and Idle Rated discrete input is detected To use the Idle Rated dynamics option the Idle Rated discrete input cannot be Always Off See the Dynamics and Discrete I O tabs Configured Idle Rated Dynamics Curve but no Idle Rated discrete in An incompatibility between the Dynamics mode and Idle Rated discrete input is detected To use the Idle Rated curve dynamics option the Idle Rated discrete input cannot be Always Off See the Dynamics and Discrete I
171. the speed control PID is not controlling to the actuator position Once the engine speed is above the run speed threshold the control will switch from start fuel demand to the fuel demand from the speed PID At this point the unit is in speed control and will control the engine to the speed setpoint The PID position during starting will be trimmed to the start fuel values therefore the switch from start fuel to PID control will be performed without a jump in position If the speed setpoint jumps the PID position could jump depending on the Gain Integral and Derivative settings of the speed PID If an error is detected the control will go to the stopping state Once the engine speed decreases to zero rpm and the stopping delay is timed out the unit will be in the stopped state Engine Starting Settings 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 Start Speed 1 Threshold Start Speed 1 Threshold is set below the starter speed On
172. tion Indication of the actual position in terms of total overall unit travel Useful if a less than full travel user calibrated range is used Full Travel Sensor Position Indication of the position in terms of total overall unit travel before linearization This value will match the TPS output 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 Indicates a logged alarm condition gt i Indicates an active alarm condition Indicates a logged shutdown condition Woodward 61 L Series Integrated Speed Control Manual 26250 x An active fault is one that is currently active or latched in the control The latching non latching faults 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 occurred but has not been reset Latched faults can be cleared by cycling power on the L Series control or by selecting the Reset Alarms and Shutdowns button on any of the Alarm or Shutdown screens Indicates an active shutdown condition A logged fault is one that occurred but is no longer currently active or latched in the control Logged faults are permanently cleared by selecting the Reset Logged Alarms and Shutdowns button on any of the Alarm or Shut
173. tion Isolation None Intended for use with external relay or other dry contact Input Threshold AUX 1 gt 3 1 Vdc ON lt 0 8 Vdc OFF Input Thresholds AUX 2 4 gt 2 Vdc ON lt 0 8 Vdc OFF Input Impedance Aux 1 10 kQ Aux 2 3 4 499 KQ 124 Woodward Manual 26250 Manual 26250 L Series Integrated Speed Conirol Discrete Output Parameter Value Output Type Low side output driver Max Contact Voltage Open 32 V Max Current 0 5A Max Contact Voltage at 0 5 A 1 5 V Closed Max Delay Time for Opening 6 5 ms Contact Default at Power Up Configurable in software Error Condition Configurable in software OK Condition Configurable in software Driving Inductive Loads Yes internally protected low side switch Protection Utilizes circuitry that will open the contact when output contacts are short circuited Self resetting when fault is removed TPS Output Parameter Value Output Type 0 5 V single ended Output Scaling 0 75 V full ccw position and 4 25 V full cw position Isolation None 3 db Circuit Bandwidth 350 Hz Transient Protection According to EMC norm Output Impedance 2 8 KQ 1 Accuracy 15 of full scale 25 C Temperature Drift 0 4 over the full temperature range I O Latency n a direct from position sensor Calibration Method Sensor in place factory calibratio
174. tion Options Configuration Parameters There are 9 different screens that display the configuration settings in the L Series speed control Overview Setpoint Control Modifiers Fuel Limiting Dynamics Discrete I O Alarm Shutdown and Security Woodward 67 L Series Integrated Speed Control Manual 26250 Overview Tab The overview tab provides speed sensing and position control configuration settings gt Configuration File Editor Configuration1 cfg 7 Dj x File Help oela aal 2 Overview Setpoint Control Modifiers Fuel Limiting Dynamics Discrete UO AlarmiShutdown Security Speed Input MPU C 2 Stroke C 4 Stroke C Ignition Number Of Cylinders 8 Number Of Cylinders Averaged 1 Number Of Teeth Per Engine Revolution 120 0 CAN Input CAN Fail Timeout 0 032 seconds CAN Device Identifier 18 Heartbeat Producer Time 0 032 seconds Position Control Min Position and Fail Direction fMin Pos and Fail Dir CCW bd A Actuator fails to maximum position Friction 25 The default gain settings are optimal for most applications Proportional Gain 11 8 Integral Gain 9 8 Derivative Gain 39 2 Figure 6 2 Configuration Editor OVERVIEW TAB Speed Input Configuration Settings These settings are used to determine the conversion from speed input pulses to engine rpm as well as engine torsional filtering Based on the security settings the speed input configuration settings with t
175. trol must return to a safe condition determined as the powered down or stopped state prior to resuming operation Failure levels lt Start Speed 2 Persistence 13 0 ms Overspeed Indication that speed was above the configured overspeed level Dedicated shutdown The control will drive to Fail Direction using position control if this fault is detected The control must return to a safe condition determined as the powered down or stopped state prior to resuming operation Failure levels gt Overspeed level configured value Persistence 6 5 ms Governing Error High Indication that speed was above the high error level for longer than the configured delay Can be configured as an alarm or shutdown If configured as a shutdown the control will drive to Fail Direction using position control if this fault is detected If configured as an alarm the control will attempt to continue normal operation if this fault is detected If faults are set to non latching this fault will not automatically reset until the control is return to a safe condition determined as the powered down or stopped state Failure levels gt Governing Error High configured level Persistence Governing Error High Delay configured value Woodward 53 L Series Integrated Speed Control Manual 26250 Governing Error Low Indication that speed was below the low error level for longer than the configured delay Can be configured as an alarm or shutdown If
176. ull stroke Does the valve fully seat close Does the valve fully open Can mid stroke be obtained and held Is the direction of the failsafe shutdown correct Does the valve move through its proper stroke smoothly Engine Generator Troubleshooting Problem Possible Cause Suggested Tesi Correction Engine does not start Stuck throttle frozen shaft Power not applied to control Run Enable not closed Fault detected in control MPU gap too large MPU signal connection open Ignition signal connection open Incorrect configuration in control Move throttle by hand Assess smoothness friction and return spring force Disconnect starter motor solenoid Disconnect harness from governor Test for 12 24 V between 12 24 V pin and ground pin Verify status of input Measure input Verify input and configuration using Service Tool Using Service Tool read configuration from control and evaluate parameters for correction Using Service Tool read faults from control Verify correct any shutdown conditions Remove and reinstall MPU per OEM s instructions Rotate engine manually to check for interference Disconnect harness from governor Test for at least 1 Vrms between MPU pin and MPU pin while the flywheel is spinning Disconnect harness from governor Test for bouncing voltage between IGN pin and ground pin while the engine is starting firing 106 Woodward Manual 2
177. upted by EMI or an internal component failure This is a normal situation Reset the error code and reset the stored errors This is an abnormal situation Return the unit to Woodward Overtemperature High internal temperature Detection of high of temperature Check ambient temperature around Control Verify temperature reading using service tool If the temperatures seem normal could indicate a problem with the temperature sensor Relay Fail Short Control detected a fault in the discrete out wiring Incorrect or intermittent wiring problem Check wiring for bad or lost connection Run Enable Shutdown Control detected that the Run Enable discrete in is not active Incorrect or intermittent wiring problem Incorrect configuration Check wiring for bad or lost connection Verify configuration Check Run Enable setting verify proper Active Open or Active Closed setting Min Fuel Limiting Indicates that the Min Fuel Limit is active Incorrect configuration Normal operation Position to speed calibration incorrect Verify configuration of fuel limit This could also be a normal indication during certain modes of operation Check with engine manufacturer Check and or perform a position calibration CAN Fault Indication that CAN messages PDO Rx are received at a rate slower than the configured minimum update rate CAN Fail Time
178. ur comments about the content of our publications Send comments to icinfo woodward com Please include the manual number from the front cover of this publication W woopDwarD PO Box 1519 Fort Collins CO 80522 1519 USA 1000 East Drake Road Fort Collins CO 80525 USA Phone 1 970 482 5811 e Fax 1 970 498 3058 Email and Website www woodward com Woodward has company owned plants subsidiaries and branches as well as authorized distributors and other authorized service and sales facilities throughout the world Complete address phone fax email information for all locations is available on our website 06 5 F
179. ut and an actual position indication see Figure 4 1 32 Woodward Manual 26250 L Series Integrated Speed Conirol Speed Input MPU or IGN eegen Configurable UO Options Isoch Load Sharing Configurable Aux1 Input gt Remote Speed Setting Configurable Aux2 Input y MAP Fuel Limiting Lower Speed Configurable Aux3 Input Raise Speed Isoch Droop Select Configurable Aux4 Input gt Idle Rated Select L Series Rated1 Rated2 Select 50 60 Hz Alternate Dynamics Select a SN Sensor Power __ Run Enable Select 10 mA max Actual Position 0 5V P Status Power Input ___ 10 32Vdc Service Tool Figure 4 1 Overview of L Series Inputs Outputs Speed Control Functions The speed control consists of a speed input speed setting logic speed biasing logic and speed dynamics options Speed Input The L Series control accommodates one speed input from either a magnetic speed pickup MPU or ignition input which 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 if MPU or number of cylinders and 2 4 stroke settings if ignition configured Speed Settings and Ramps The L Series provides for local speed setpoint control by discrete
180. ut off valve is highly recommended Failure to comply with this recommendation can cause personal injury and or property damage Use of an external spring to return to minimum fuel is highly recommended Failure to comply with this recommendation can cause personal injury and or property damage Use of a predicted min fuel shutdown procedure is highly recommended Failure to comply with this recommendation can cause personal injury L Series Integrated Speed Control Manual 26250 Unpacking Be careful when unpacking the actuator Check the unit for signs of damage such as bent or dented panels scratches and loose or broken parts Notify the shipper and Woodward if damage is found Mechanical Installation Mounting Location NOTE To meet ATEX Hazardous Location requirements the installer of the L series must take responsibility for meeting Sub Clause 26 3 3 1 of EN60079 15 2003 regarding impact testing The actuator by itself does not meet this requirement and therefore must be sufficiently protected when installed According to EN60079 15 the protection must be such that a 1 kg mass fitted with an impact head in the form of a hemisphere of 25 mm diameter can be dropped vertically from a height of 0 7 meter and not cause significant damage to the actuator Locate the L Series control a distance from sources of extreme radiant heat such as exhaust manifolds or turbochargers The operating temperature range of the control
181. ward equipment based on the standard Woodward Product and Service Warranty 5 01 1205 that is in effect at the time the product is purchased from Woodward or the service is performed e Replacement Exchange 24 hour service e Flat Rate Repair e Flat Rate Remanufacture If you are experiencing problems with installation or unsatisfactory performance of an installed system the following options are available e Consult the troubleshooting guide in the manual e Contact Woodward technical assistance see How to Contact Woodward later in this chapter and discuss your problem In most cases your problem can be resolved over the phone If not you can select which course of action you wish to pursue based on the available services listed in this section 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 is also a flat rate structured program and includes the full standard Woodward product warranty Woodward Product and Service Warranty 5 01 1205 This option allows you to call 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 ca
182. x 1519 1000 East Drake Rd Fort Collins CO 80522 1519 USA Telephone 1 970 482 5811 24 hours a day Toll free Phone in North America 1 800 523 2831 Fax 1 970 498 3058 For assistance outside North America call one of the following international Woodward facilities to obtain the address and phone number of the facility nearest your location where you will be able to get information and service Facility Phone Number Brazil 55 19 3708 4800 India 91 129 230 7111 Japan 81 476 93 4661 The Netherlands 31 23 5661111 You can also contact the Woodward Customer Service Department or consult our worldwide directory on Woodward s website www woodward com for the name of your nearest Woodward distributor or service facility 118 Woodward Manual 26250 L Series Integrated Speed Conirol Engineering Services Woodward Industrial Controls Engineering Services offers the following after sales support for Woodward products For these services you can contact us by telephone by email or through the Woodward website e Technical Support e Product Training e Field Service Contact information Telephone 1 970 482 5811 Toll free Phone in North America 1 800 523 2831 Email icinfo woodward com Website www woodward com Technical Support is available through our many worldwide locations or our authorized distributors depending upon the product This service can assist you with technical questions or
183. x2 active open Aux3 active open Aux 4 active open Always On CAN 5418 2226 software only nn NT L Series Integrated Speed Conirol Any unused function is typically turned off by selecting Always Off the exception to this is the Run Enable which requires an Always On selection or the control will never run Selecting Active Closed for a function will activate a function whenever the aux input voltage is above the ON threshold refer to the Specifications section for On and Off thresholds Likewise selecting Active Open will activate the function when the aux input is below the OFF threshold An Active Closed setting is recommended Input Configuration Settings Raise Select the desired input for this function Lower Select the desired input for this function Dual Dynamics Select the desired input for this function Idle Rated Select the desired input for this function Rated 2 Select the desired input for this function Droop Select the desired input for this function Run Enable Select the desired input for this function WARNING FAULT PROTECTION It is recommended that all inputs be configured for the failsafe Active Closed mode to ensure maximum fault protection Woodward 85 L Series Integrated Speed Control Manual 26250 Output Settings Relay Output Configuration The relay output can be configured to one of the followin
184. y in seconds before the dynamics actually changes to the selected set either from dynamics 1 to dynamics 2 or vice versa Allowed values 0 425 s 82 Woodward Manual 26250 L Series Integrated Speed Conirol 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 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 will be 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 Discrete I O tab Rated Curve the gain term will be adjusted based on actuator position using a 5 pt curve Fuel demand is roughly proportional to load but not necessarily in a linear mann
185. z Isolation None Input Impedance 113 kO Accuracy 0 25 of point controlled engine speed in rpm over the temperature range of 40 to 125 C including drift for gasoline diesel and gaseous engines I O Latency 6 5 ms Out of Range Frequency 12 kHz is maximum sensed frequency Out of range is determined by user configured overspeed and start speed settings See Chapter 6 for configuration IGN Input Parameter Value Input Magnitude 200 to 250 V Max 100 to 150 V Min Frequency Range 1 480 Hz Isolation None Input Impedance 44 113 kQ Accuracy 0 5 of point controlled engine speed in rpm over the temperature range of 40 to 125 C including drift for both gasoline and gaseous applications I O Latency 6 5 ms Discrete Input Out of Range Frequency 480 Hz Max will not sense above this Out of range is determined by user configured overspeed and start speed settings See Chapter 6 for configuration Parameter Value Aux 1 Input Current 0 5 mA 5 Vdc Aux 2 3 4 Input Current 10 pA 5V Input Type Ground referenced discrete input Delay Time for Shutdown lt 200 ms for system to recognize shutdown if used for run stop input Delay Time for Reset lt 1 s for valves to move to minimum position if used for Detection run stop input Max Voltage from 32 V power input voltage Connec

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